CSP Hmi 2 - I0r43tr10002p PDF

MD Helicopters, Inc.
MAINTENANCE MANUAL
MD HELICOPTERS INC.
CSP-HMI-2
HANDBOOK OF MAINTENANCE
INSTRUCTIONS
FOR
MDHI 369D/E/FF - 500/600N HELICOPTERS

ISSUED: 31 OCTOBER 1990
NOTE
This manual has been reprinted and now contains

Revisions 1 through 43 (23 December 2009),
Temporary Revision TR10-001 (12 March 2010) and
Temporary Revision TR10-002 (3 May 2010)
PRINT DATE: 10 May 2010

MDHI MODEL HELICOPTERS
MODELS 369D/E/FF 500/600N
Basic Handbook of Maintenance Instructions

(CSPHMI2)
SERVICING AND MAINTENANCE
4555 East McDowell Road
Mesa, Arizona 852159734
Copyright E 19992010 by MD Helicopters, Inc. Issued: 31 October 1990

All rights reserved under the copyright laws. Revision No. 43: 23 December 2009
PROPRIETARY RIGHTS NOTICE
The technical data and information contained in this publication is the property of
and proprietary to MD Helicopters, Inc. and is not to be disclosed or reproduced in
whole or in part without the written consent of MD Helicopters, Inc.
RESTRICTED USE
MDHI provides this manual for use by owners, operators and maintainers of MDHI
products and authorized parts. Use by STC or PMA applicants or holders as
documentation to support their certificates is not an authorized use of this manual
and is prohibited. MDHI takes no responsibility for customers use of parts
manufactured under an STC or PMA when this manual is used as documentation with
the Federal Aviation Administration to justify the STC or PMA. Use of unauthorized
parts on MDHI products will void the MDHI warranty offered to the customer on
components and may void the warranty on the helicopter.
Mesa, Arizona 852159734
MD HELICOPTER, INC.
TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
This manual has been prepared and distributed by the Technical Publications Department and is
intended for use by personnel responsible for the maintenance of MDHI Helicopters. Periodic revision
of this manual will be made to incorporate the latest information. If, in the opinion of the reader, any
information has been omitted or requires clarification, please direct your comments to this office via
this form (or a duplicate). An endeavor will be made to include such information in future revisions.
Bldg 615 M/S G048
Mesa, AZ 852159734
Telephone: (800) 3108539
Technical Publications Order Desk: (480) 3466372; FAX: (480) 3466821
Technical Publications Changes: (480) 3466212; FAX: (480) 3466809
Date:
Originator:
Address:
EMail:
Manual Title: Page Number(s):
Chapter Title: Paragraph Number(s):
ATA Section Number: Step Number(s):
Issue Date:
Figure Number(s):
Revision No. and Date: Table Number(s):
Remarks / Instructions:
Page CRi
This Page Intentionally Left Blank
Page CRii
MD Helicopters, Inc. CSPHMI2
MAINTENANCE MANUAL
RECORD OF TEMPORARY REVISIONS
Rev. Date Date Rev. Date Date

No. Inserted By Removed By No. Inserted By Removed By
91001 Removed by 95003 Removed by

Revision 3 Revision 13
















Page 1
TR Revision 42
CSPHMI2 MD Helicopters, Inc.
MAINTENANCE MANUAL
Rev. Date Date Rev. Date Date

No. Inserted By Removed By No. Inserted By Removed By
03004 Removed by
Revision 35
04001 Removed by
Revision 36
05001 Removed by
Revision 37
05002 Removed by
Revision 38
06001 Removed by
Revision 39
07001 Removed by
Revision 40
08001 Removed by
Revision 42
08002 Removed by
Revision 42
09001 Removed by
Revision 42
10001 03/12/10 GH
10002 05/03/10 GH
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Revision 42 TR
MAINTENANCE MANUAL
LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES
The highest revision number indicates pages changed, added or removed by the current change.
Date of original and revision pages are:
Original . . . . . . . . . . . . . . . . . . . . 31 October 1990 Revision 22 . . . . . . . . . . . . . . . . . . . 10 March 1998
Revision 1 . . . . . . . . . . . . . . . . . . . . 29 March 1991 Revision 23 . . . . . . . . . . . . . . . . . . . . 01 June 1999
Revision 2 . . . . . . . . . . . . . . . . . . . . . . 10 May 1991 Revision 24 . . . . . . . . . . . . . . . 07 December 1999
Revision 3 . . . . . . . . . . . . . . . . 09 September 1991 Revision 25 . . . . . . . . . . . . . . . . . . . . . 28 April 2000
Revision 4 . . . . . . . . . . . . . . . . . . 20 January 1992 Revision 26 . . . . . . . . . . . . . . . . . . 17 August 2000
Revision 5 . . . . . . . . . . . . . . . . . . . 24 August 1992 Revision 27 . . . . . . . . . . . . . . . . . 09 October 2000
Revision 6 . . . . . . . . . . . . . . . . 21 December 1992 Revision 28 . . . . . . . . . . . . . . . 30 November 2000
Revision 7 . . . . . . . . . . . . . . . . . . . . . 01 June 1993 Revision 29 . . . . . . . . . . . . . . . . . . . . . 11 May 2001
Revision 8 . . . . . . . . . . . . . . . . . . . . . . 23 July 1993 Revision 30 . . . . . . . . . . . . . . . . . . . . . 11 July 2001
Revision 9 . . . . . . . . . . . . . . . . . . . . . . 22 April 1994 Revision 31 . . . . . . . . . . . . . . . 05 November 2001
Revision 10 . . . . . . . . . . . . . . . 26 September 1994 Revision 32 . . . . . . . . . . . . . . . . . . . 18 March 2002
Revision 11 . . . . . . . . . . . . . . . . . 18 January 1995 Revision 33 . . . . . . . . . . . . . . . . . . . . 24 June 2002
Revision 12 . . . . . . . . . . . . . . . . . 06 October 1995 Revision 34 . . . . . . . . . . . . . . . . . . 21 August 2003
Revision 13 . . . . . . . . . . . . . . . . . . . . . 31 May 1996 Revision 35 . . . . . . . . . . . . . . . . . . . . . 20 May 2004
Revision 14 . . . . . . . . . . . . . . . 13 September 1996 Revision 36 . . . . . . . . . . . . . . . 11 November 2004
Revision 15 . . . . . . . . . . . . . . . 15 November 1996 Revision 37 . . . . . . . . . . . . . . . 13 December 2005
Revision 16 . . . . . . . . . . . . . . . . . 06 January 1997 Revision 38 . . . . . . . . . . . . . . . . . . . . . 25 May 2006
Revision 17 . . . . . . . . . . . . . . . . . 24 February 1997 Revision 39 . . . . . . . . . . . . . . . . . . . . . 10 April 2007
Revision 18 . . . . . . . . . . . . . . . . . 17 October 1997 Revision 40 . . . . . . . . . . . . . . . 10 November 2007
Revision 19 . . . . . . . . . . . . . . . 16 December 1997 Revision 41 . . . . . . . . . . . . . . . . . . . 03 March 2008
Revision 20 . . . . . . . . . . . . . . . . . . . . 01 June 1998 Revision 42 . . . . . . . . . . . . . . . . . . . . 01 June 2009
Revision 21 . . . . . . . . . . . . . . . . . . 24 August 1998 Revision 43 . . . . . . . . . . . . . . . 23 December 2009
Cover/Title Chapter 01
Cover/Title . . . . . . . . . . . . . . . . . . . . . . Revision 43 i................................ Revision 26
Change Request ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
CRi and CRii . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A 010000
Temporary Revision 1 ............................... Revision 26
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
List of Effective Pages 7 ............................... Revision 29
A thru J . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43 8 ............................... Revision 28
Table of Contents 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
i................................ Revision 42 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 203 thru 214 . . . . . . . . . . . . . . . . . . . . . Revision 43
iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
v and vi . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
Page A
LOEP Revision 43
MAINTENANCE MANUAL
Chapter 04 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36

i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
040000 Chapter 07
1 thru 16 . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 i................................ Revision 23
040001 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
1 ............................... Revision 26 070000
2 ............................... Revision 43 201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 23
Chapter 05 Chapter 08
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 i................................ Revision 23
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
050000
1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38 080000
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
051000
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
1 ............................... Revision 34
081000
2 ............................... Revision 40
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
3 ............................... Revision 37
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 27
4 ............................... Revision 34
204 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23
052000 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
2 ............................... Revision 39 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
3 ............................... Revision 40 Chapter 09
4 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 35 i................................ Revision 23
7 thru 12 . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
052010 090000
1 thru 3 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
052015 i................................ Revision 23
1 ............................... Revision 29 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
2 ............................... Revision 43 101000
4 ............................... Revision 43 102000
052020 201 thru 203/(204 blank) . . . . . . . . . . Revision 23
1 ............................... Revision 43 103000
4 ............................... Revision 43 i................................ Revision 23
5 ............................... Revision 38 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
6 ............................... Revision 36 110000
055000 201 thru 217/(218 blank) . . . . . . . . . . Revision 23
1 thru 12 . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 114000
Chapter 06 201 thru 211/(212 blank) . . . . . . . . . . Revision 23
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 Chapter 12
060000 i................................ Revision 23
201 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 23 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 120000
207 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23 301 and 302 . . . . . . . . . . . . . . . . . . . . . Revision 23
Page B
Revision 43 LOEP
MAINTENANCE MANUAL
303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 203000

304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23
305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26 203 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 34
306 and 307 . . . . . . . . . . . . . . . . . . . . . Revision 24
204000
308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
310 and 311 . . . . . . . . . . . . . . . . . . . . . Revision 32 209000
312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
Chapter 18 202 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 40
i thru iii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 Chapter 21
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
181000
211000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 37 214000
401 thru 404 . . . . . . . . . . . . . . . . . . . . . Revision 23 201 thru 207 . . . . . . . . . . . . . . . . . . . . . Revision 23
503 thru 505 . . . . . . . . . . . . . . . . . . . . . Revision 23 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
506 and 507 . . . . . . . . . . . . . . . . . . . . . Revision 24 901 thru 911/(912 blank) . . . . . . . . . . Revision 23
508 and 509 . . . . . . . . . . . . . . . . . . . . . Revision 23
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 Chapter 25
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
181060
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 ii thru vii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
202 and 203/(204 blank) . . . . . . . . . . Revision 31 viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
401 thru 404 . . . . . . . . . . . . . . . . . . . . . Revision 23 250000
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
251000
503 thru 509 . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 23
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
511 and 512 . . . . . . . . . . . . . . . . . . . . . Revision 23
207 and 208 . . . . . . . . . . . . . . . . . . . . . Revision 23
182000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 251500
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 23 201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 252000
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 201 thru 211/(212 blank) . . . . . . . . . . Revision 23
182030
252100
201 thru 205/(206 blank) . . . . . . . . . . Revision 23
201/(202 blank) . . . . . . . . . . . . . . . . . . Revision 23
Chapter 20
901 thru 908 . . . . . . . . . . . . . . . . . . . . . Revision 23
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 41
201000 253000
202000 254000
Page C
LOEP Revision 43
MAINTENANCE MANUAL
255000 280060
101 thru 106 . . . . . . . . . . . . . . . . . . . . . Revision 23 1 thru 3/(4 blank) . . . . . . . . . . . . . . . . . Revision 19
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 23 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
901 thru 907/(908 blank) . . . . . . . . . . Revision 23 103/(104 blank) . . . . . . . . . . . . . . . . . . Revision 21
256000 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
401 thru 405 . . . . . . . . . . . . . . . . . . . . . Revision 19
256300
406 and 407 . . . . . . . . . . . . . . . . . . . . . Revision 34
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 501 and 502 . . . . . . . . . . . . . . . . . . . . . Revision 22
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43 503/(504 blank) . . . . . . . . . . . . . . . . . . Revision 21
261000 601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
201 thru 203/(204 blank) . . . . . . . . . . Revision 23 602 thru 605 . . . . . . . . . . . . . . . . . . . . . Revision 31
606 thru 608 . . . . . . . . . . . . . . . . . . . . . Revision 43
262000
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23
282500
Chapter 28
1 ............................... Revision 39
i................................ Revision 19
2 ............................... Revision 20
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37 101/(102 blank) . . . . . . . . . . . . . . . . . . Revision 20
iii and iv . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 20
v ............................... Revision 31 203 thru 205/(206 blank) . . . . . . . . . . Revision 19
vi thru viii . . . . . . . . . . . . . . . . . . . . . . . . Revision 43 601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 20
280000 901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 20
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19 903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
102 and 103 . . . . . . . . . . . . . . . . . . . . . Revision 19 Chapter 32
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 19 ii thru vi . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
401 thru 414 . . . . . . . . . . . . . . . . . . . . . Revision 19 321000
415 and 416 . . . . . . . . . . . . . . . . . . . . . Revision 36 1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 19
507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 406 and 407/(408 blank) . . . . . . . . . . Revision 26
601 thru 603 . . . . . . . . . . . . . . . . . . . . . Revision 19 602 thru 605/(606 blank) . . . . . . . . . . Revision 26
605 thru 607/(608 blank) . . . . . . . . . . Revision 19 806 and 807/(808 blank) . . . . . . . . . . Revision 26
Page D
Revision 43 LOEP
MAINTENANCE MANUAL
321060 531000
1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 19 201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 19
301 thru 303/(304 blank) . . . . . . . . . . Revision 19 532000
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26 533000
405 and 406 . . . . . . . . . . . . . . . . . . . . . Revision 19 204 thru 214 . . . . . . . . . . . . . . . . . . . . . Revision 38
407/(408 blank) . . . . . . . . . . . . . . . . . . Revision 20 533030
603/(604 blank) . . . . . . . . . . . . . . . . . . Revision 22 534000
324000 534030
324060 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 19
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
328100 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 19
205 thru 214 . . . . . . . . . . . . . . . . . . . . Revision 39
901 thru 910 . . . . . . . . . . . . . . . . . . . . . Revision 19
328200
535010
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 19
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 19
Chapter 52 204 and 205 . . . . . . . . . . . . . . . . . . . . . Revision 37
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
521000 207/(208 blank) . . . . . . . . . . . . . . . . . . Revision 19
201 thru 213 . . . . . . . . . . . . . . . . . . . . . Revision 25 535030
524000 Chapter 62
201 thru 205/(206 blank) . . . . . . . . . . Revision 18 i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37
620000
525000
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 18
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
621000
208 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 18
i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40 606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
530000 607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
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801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 623000

810 and 811/(812 blank) . . . . . . . . . . Revision 20 403 and 404 . . . . . . . . . . . . . . . . . . . . . Revision 31
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
622000
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
407 and 408 . . . . . . . . . . . . . . . . . . . . . Revision 35
402 and 403 . . . . . . . . . . . . . . . . . . . . . Revision 20 601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 32
405 and 406 . . . . . . . . . . . . . . . . . . . . . Revision 20 623060
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37 407/(408 blank) . . . . . . . . . . . . . . . . . . Revision 20
803 thru 810 . . . . . . . . . . . . . . . . . . . . . Revision 20 i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
811 thru 813 . . . . . . . . . . . . . . . . . . . . . Revision 37 630000
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
817 and 818 . . . . . . . . . . . . . . . . . . . . . Revision 40
631000
819 and 820 . . . . . . . . . . . . . . . . . . . . . Revision 37
401 thru 403 . . . . . . . . . . . . . . . . . . . . . Revision 20
622060 404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
405/(406 blank) . . . . . . . . . . . . . . . . . . Revision 20 408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
604 thru 606 . . . . . . . . . . . . . . . . . . . . . Revision 20
610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
801 thru 804 . . . . . . . . . . . . . . . . . . . . . Revision 20
801 thru 804 . . . . . . . . . . . . . . . . . . . . . Revision 20
631510
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410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 632510

605/(606 blank) . . . . . . . . . . . . . . . . . . Revision 20 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
631530
632530
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
203 thru 207 . . . . . . . . . . . . . . . . . . . . . Revision 20
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
632000
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 20 633000
206 and 207/(208 blank) . . . . . . . . . . Revision 20 203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 36
632025 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
206 thru 209/(210 blank) . . . . . . . . . . Revision 29 640000
632100 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 640005
408 thru 410 . . . . . . . . . . . . . . . . . . . . . Revision 42 641000
411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
202 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 21
413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37 642000
804 and 805 . . . . . . . . . . . . . . . . . . . . . Revision 36
642530
806 and 807 . . . . . . . . . . . . . . . . . . . . . Revision 37
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 41
808 and 809 . . . . . . . . . . . . . . . . . . . . . Revision 36
404 thru 407 . . . . . . . . . . . . . . . . . . . . . Revision 41
632200
401 thru 413/(414 blank) . . . . . . . . . . Revision 20 801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
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643000 525 and 526 . . . . . . . . . . . . . . . . . . . . . Revision 36

208 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 21
605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
Chapter 67 606 and 607 . . . . . . . . . . . . . . . . . . . . . Revision 39
i thru xii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
670000 609 and 610 . . . . . . . . . . . . . . . . . . . . . Revision 39
102 and 103 . . . . . . . . . . . . . . . . . . . . . Revision 21
814 and 815 . . . . . . . . . . . . . . . . . . . . . Revision 31
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
816 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
105 and 106 . . . . . . . . . . . . . . . . . . . . . Revision 42
107 thru 111 . . . . . . . . . . . . . . . . . . . . . Revision 30 671020
671000 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
1 thru 5/(6 blank) . . . . . . . . . . . . . . . . . Revision 21 204 thru 208 . . . . . . . . . . . . . . . . . . . . . Revision 21
401 thru 405 . . . . . . . . . . . . . . . . . . . . . Revision 21 672010
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
415 thru 417 . . . . . . . . . . . . . . . . . . . . . Revision 29
501 thru 504 . . . . . . . . . . . . . . . . . . . . . Revision 21
418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 21
419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21 672030
422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 1 ............................... Revision 34
506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
508 and 509 . . . . . . . . . . . . . . . . . . . . . Revision 21
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
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506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
510 and 511 . . . . . . . . . . . . . . . . . . . . . Revision 30
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 35
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 711060
604 and 605 . . . . . . . . . . . . . . . . . . . . . Revision 24 1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 22
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
101/(102 blank) . . . . . . . . . . . . . . . . . . Revision 22
801 thru 803 . . . . . . . . . . . . . . . . . . . . . Revision 18
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36 601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
710000 602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33
1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 22
401 thru 405 . . . . . . . . . . . . . . . . . . . . . Revision 22 712000
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 30
1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 22
407 thru 411 . . . . . . . . . . . . . . . . . . . . . Revision 22
412 and 413/(414 blank) . . . . . . . . . . Revision 26 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
710030 402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 22 403 and 404 . . . . . . . . . . . . . . . . . . . . . Revision 34
401 thru 404 . . . . . . . . . . . . . . . . . . . . . Revision 22
405/(406 blank) . . . . . . . . . . . . . . . . . . Revision 22
405 and 406 . . . . . . . . . . . . . . . . . . . . . Revision 34
407 thru 411 . . . . . . . . . . . . . . . . . . . . . Revision 22 601/(602 blank) . . . . . . . . . . . . . . . . . . Revision 22
710047
1 thru 3/(4 blank) . . . . . . . . . . . . . . . . . Revision 22 713000
401 thru 406 . . . . . . . . . . . . . . . . . . . . . Revision 22 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
401 thru 410 . . . . . . . . . . . . . . . . . . . . . Revision 22
711000
711005 412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
201/(202 blank) . . . . . . . . . . . . . . . . . . Revision 22 413 and 414 . . . . . . . . . . . . . . . . . . . . . Revision 26
901 thru 904 . . . . . . . . . . . . . . . . . . . . . Revision 22
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 32
711010
2 ............................... Revision 36 901 thru 905/(906 blank) . . . . . . . . . . Revision 22
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
101 thru 106 . . . . . . . . . . . . . . . . . . . . . Revision 36 716000
201 thru 207/(208 blank) . . . . . . . . . . Revision 22 201 thru 205/(206 blank) . . . . . . . . . . Revision 22
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i................................ Revision 22 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43 Chapter 78
751000 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 35
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 22 782000
205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 22
Chapter 76
783000
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
760000 202 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 35
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
Chapter 79
101 and 102 . . . . . . . . . . . . . . . . . . . . . Revision 22
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
761000
201 thru 214 . . . . . . . . . . . . . . . . . . . . . Revision 22 790000
216 and 217 . . . . . . . . . . . . . . . . . . . . . Revision 42 791010
222 and 223 . . . . . . . . . . . . . . . . . . . . . Revision 35 Chapter 91
224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
762000 910000
201 thru 213/(214 blank) . . . . . . . . . . Revision 22 1 ............................... Revision 23
764700 2 ............................... Revision 34
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 37 4 thru 16 . . . . . . . . . . . . . . . . . . . . . . . . Revision 41
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 37 18 thru 20 . . . . . . . . . . . . . . . . . . . . . . . Revision 43
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22 21 and 22 . . . . . . . . . . . . . . . . . . . . . . . Revision 41
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TABLE OF CONTENTS
CSPHMI2
Cover / Title Page
Technical Manual Recommended Change Report
Record of Temporary Revisions
List of Effective Pages
01 Introduction
04 Airworthiness Limitations
05 Continued Airworthiness Checks / Inspections
06 Dimensions and Areas
07 Lifting and Jacking
08 Leveling / Weight and Balance
09 Towing
10 Parking and Mooring
11 Placards and Markings
12 Servicing
18 Vibration and Noise Analysis
20 Standard Practices
21 Environmental Control System
25 Equipment / Furnishings
26 Fire Protection
28 Fuel System
32 Landing Gear
52 Doors
53 Fuselage
62 Main Rotor
63 Transmission and Drive System
64 AntiTorque Assembly
67 Flight Controls
71 Power Plant
75 Engine AntiIce System
76 Engine Power Controls
78 Engine Exhaust System
79 Engine Oil Supply System
91 Charts
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CSPHMI3
95 Instruments
96 Electrical Power
97 Avionics
Page ii
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NOTE: The following sections are applicable to the helicopter models denoted to the right of the
section.
Section Title 369D 369E 369FF 500N 600N
01 INTRODUCTION
010000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
04 AIRWORTHINESS LIMITATIONS
040000 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
040001 Airworthiness Limitations Supplements . . . . . . . . . . . . . . . . . . . . . . X
05 CONTINUED AIRWORTHINESS
050000 Checks/Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
051000 Component Overhaul/Recommended Replacement . . . . . . . . . . X X X X X
052000 100Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
052010 300Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
052015 Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
052020 Special Inspections Hourly and Calendar . . . . . . . . . . . . . . . . . . . . X X X X X
055000 Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
06 DIMENSIONS AND AREAS

060000 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
07 LIFTING AND JACKING

070000 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
08 LEVELING / WEIGHT AND BALANCE

080000 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
081000 Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
09 TOWING
090000 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
10 PARKING AND MOORING

101000 Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
102000 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
103000 Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
11 PLACARDS AND MARKINGS

110000 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
114000 Placards and Markings (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
12 SERVICING
120000 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
18 VIBRATION AND NOISE ANALYSIS

181000 Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
181060 Main Rotor Track and Balance (600N) . . . . . . . . . . . . . . . . . . . . . . X
182000 Tail Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
182030 Notarr AntiTorque System Fan Balance . . . . . . . . . . . . . . . . . . . . X X
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20 STANDARD PRACTICES
201000 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
202000 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
203000 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
204000 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
209000 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
21 ENVIRONMENTAL CONTROL SYSTEM

211000 Ventilation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
214000 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25 EQUIPMENT / FURNISHINGS
250000 Equipment/Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
251000 Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
251500 Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
252000 Seat Belts/Inertia Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
252100 Seating/Belts (Four on the Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
253000 Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
254000 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
255000 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
256000 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
256300 Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
26 FIRE PROTECTION
261000 Engine Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
262000 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
28 FUEL SYSTEM
280000 Fuel System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
280060 Fuel System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
282500 AntiIce / Airframe Fuel Filter (369D/E 500/600N) . . . . . . . . . . X X X X X
32 LANDING GEAR
321000 Landing Gear System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . X X X X
321060 Landing Gear System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
324000 Ground Handling Wheels (369D/E/FF 500N) . . . . . . . . . . . . . . . X X X X
324060 Ground Handling Wheels (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . X
328100 Utility Float System (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
328200 Emergency Float System (369D/E/FF 500N) . . . . . . . . . . . . . . . X X X X
52 DOORS
521000 Crew, Passenger, Cargo Doors and Windows . . . . . . . . . . . . . . . . X X X X X
524000 Engine Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
525000 Miscellaneous Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
Page iv
MAINTENANCE MANUAL

53 FUSELAGE
530000 Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
531000 Windshields and Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . X X X X X
532000 Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
533000 Upper Aft Section Fuselage (369D/E/FF) . . . . . . . . . . . . . . . . . . . . X X X
533030 Upper Aft Section Fuselage (500/600N) . . . . . . . . . . . . . . . . . . . . . X X
534000 Tailboom (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
534030 Tailboom (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
535010 Stabilizer (TTail) (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
535030 Stabilizer (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
62 MAIN ROTOR
620000 Main Rotor (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
621000 Main Rotor Blade (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . X X X X X
622000 Main Rotor Hub (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . X X X X
622060 Main Rotor Hub (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
623000 Swashplate and Mixer (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . X X X X
623060 Swashplate and Mixer (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
63 TRANSMISSION AND DRIVE SYSTEM
630000 Transmission and Drive System (369D/E/FF 500/600N) . . . . . X X X X X
631000 Drive Shafts / Clutches / Couplings (369D/E/FF 500/600N) . . X X X X X
631510 Tail Rotor Drive Shaft (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . X X X
631530 NOTARr AntiTorque System Drive Shafts (500/600N) . . . . . . . X X
632000 369D25100 Main Transmission (369D/E/FF 500N) . . . . . . . . . . X X X X
632025 369F5100 Main Transmission (369D/E/FF 500/600N) . . . . . . . X X X X X
632100 Main Transmission Lubrication and Cooling System
(369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
632200 Rotor Brake (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . X X X X X
632510 Tail Rotor Transmission (Two and Four Blade) (369D/E/FF) . . . . X X X
632530 NOTARr AntiTorque Fan Transmission (500/600N) . . . . . . . . . . X X
633000 Main Rotor Static Mast (369D/E/FF 500/600N) . . . . . . . . . . . . . X X X X X
64 ANTITORQUE ASSEMBLY
640000 AntiTorque Assembly (369D/E/FF 500/600N) . . . . . . . . . . . . . X X X X X
640005 FourBladed Tail Rotor Assembly Initial Installation (369D/E) . . X X
641000 Tail Rotor Blades (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
642000 Tail Rotor Hub and Fork (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . X X X
642530 AntiTorque Fan (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
643000 Tail Rotor Pitch Control Assembly (369D/E/FF) . . . . . . . . . . . . . . . X X X
67 FLIGHT CONTROLS
670000 Flight Controls (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . X X X X X
671000 Main Rotor Flight Controls (369D/E/FF 500/600N) . . . . . . . . . . X X X X X
671020 Collective and Cyclic Stick Grips (369D/E/FF 500/600N) . . . . . X X X X X
672010 AntiTorque Flight Controls (Two and Four Blade)
(369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
672030 NOTARr AntiTorque System Flight Controls (500/600N) . . . . . X X
Page v
MAINTENANCE MANUAL
71 POWER PLANT
710000 Power Plant (250C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
710030 Power Plant (250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
710047 Power Plant (250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
711000 Engine Air Intake System (369D/E/FF 500/600N) . . . . . . . . . . . X X X X X
711005 Engine Compressor Water Wash Kit (369D/E/FF
500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
711010 Engine Air Particle Separator (369D/E/FF 500N) . . . . . . . . . . . X X X X
711060 Engine Air Particle Separator (600N) . . . . . . . . . . . . . . . . . . . . . . . X
712000 Engine Mounts (250C20B, 250C20R/2, 250C30
and 250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
713000 Engine Ignition Control System (250C20B, 250C20R/2
and 250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
716000 Engine Cooling System (250C20B, 250C20R/2, 250C30
and 250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
75 ENGINE ANTIICE SYSTEM

751000 Engine AntiIcing System (250C20B, 250C20R/2,
250C30 and 250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
76 ENGINE POWER CONTROLS

760000 Engine Power Controls (250C20B, 250C20R/2
and 250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
761000 Power Turbine Governor Controls (250C20B, 250C20R/2
and 250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
762000 Gas Producer Controls (250C20B, 250C20R/2 and
250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
764700 Engine Power Controls (250C47) . . . . . . . . . . . . . . . . . . . . . . . . . X
78 ENGINE EXHAUST SYSTEM

782000 Engine Exhaust System (250C20B and 250C20R/2) . . . . . . . . X X X
783000 Engine Exhaust System (250C30 and 250C47) . . . . . . . . . . . . X X
79 ENGINE OIL SUPPLY SYSTEM

790000 Engine Oil Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
791010 Engine Scavenge Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
91 CHARTS
910000 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
Page vi
MAINTENANCE MANUAL
Chapter
01
Introduction
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
010000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Proprietary Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. 369D/E/FF 500/600N Helicopter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Helicopter Major Components (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . 2
4. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Division of Subject Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. Figure and Table Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9. Associated MDHI Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. Illustrated Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Component Overhaul Manual (Overhaul Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Structural Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10. Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11. MDHI Publications Changes and Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Reprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Service Information Notices and Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12. Application of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13. Service and Operations Report Form 1601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Maintenance and Operational Check Requirements and Precautions . . . . . . . . . . . 201
A. Pilots or Rotorcraft Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Maintenance Information Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Related Publications and Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 202. Optional Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Page i
01 Contents Revision 26
MAINTENANCE MANUAL
TABLE OF CONTENTS (Cont.)

Page ii
Revision 43 01 Contents
MAINTENANCE MANUAL
Section
010000
Introduction
MAINTENANCE MANUAL
INTRODUCTION
DESCRIPTION AND OPERATION
1. Proprietary Rights permits the main rotor to freewheel for
autorotational descent.
MD Helicopters, Inc. proprietary rights are
included in the information disclosed herein. The fuselage is a semimonocoque construc-
Recipient, by accepting this document, agrees tion divided into three sections. The structure
that neither this document nor any part consists of a central framework, a mast
thereof shall be reproduced or transferred to support structure, two bulkheads and a center
other documents or used or disclosed to others beam. The forward section includes the crew
for manufacturing or any other purpose, and cargo or passenger compartment. The
except as specifically authorized in writing by crew compartment is equipped with seats for
MD Helicopters, Inc. All rights are reserved the pilot and either one or two passengers. The
under the copyright laws by MD Helicopters, crew compartment left seat is the pilots seat
Inc. (LH command position) except in a RH
command configuration helicopter. The cargo
2. Introduction compartment is behind the crew compartment
and contains provisions for benchtype or
folding passenger seats. Passenger seats may
All helicopters described in this manual are be folded out of the way or completely removed
manufactured by MD Helicopters Inc. (MDHI), to accommodate cargo. The aft section houses
Mesa, Arizona. The design features and the engine and includes structure for tailboom
performance characteristics of all helicopters attachment and in the case of the 500/600N,
are essentially the same. The main differences the fan assembly and fan transmission for the
between helicopters are the type and arrange- NOTARR antitorque system. The lower
ment of interior furnishings and equipment, section is divided by a center beam and
the pilots flight control position, engine power, provides two bays containing two fuel cells
antitorque system and a variety of optional that make up the fuel tank.
equipment.
The 369D/E/FF tailboom is a monocoque
3. 369D/E/FF 500/600N Helicopter structure of aluminum alloy frames and skin.
Description The tailboom is the supporting structure for
the vertical and horizontal stabilizers, tail
NOTE: Throughout this manual, references to rotor transmission and tail rotor. The tailboom
the 369FF model helicopters also includes also houses the tail rotor transmission drive
the 369F model helicopters, unless other- shaft and tail rotor bladeangle control rod.
wise stated.
The 500/600N tailboom assembly is a fully
(Ref. Figure 1) The Model 369D/E/FF monocoque construction of carbon fiber
500/600N helicopters are turbinepowered, composites. The tailboom is the supporting
rotarywing aircraft constructed primarily of structure for the stator assembly, horizontal
aluminum alloy. The main rotor system for the stabilizer, two thruster assemblies and control
369D/E/FF 500N helicopter is fivebladed cable assembly.
and fullyarticulated. The main rotor system
for the 600N helicopter is sixbladed and The main rotor group consists of five or six
fullyarticulated. The antitorque system may main rotor blades, a fullyarticulated main
be two bladed, an optional fourbladed rotor hub with offset flapping hinges, a
installation or a NOTARR antitorque system. scissors assembly, and a swashplate and
Engine output is delivered to the main and associated mixer control mechanisms. The
antitorque system by drive shafts and two main rotor blades are secured to the rotor hub
transmissions. A oneway overrunning clutch with standard hardware and quickrelease
between the engine and main transmission pins.
Page 1
010000 Revision 26
MAINTENANCE MANUAL
HORIZONTAL STABILIZER
MAIN ROTOR INSTALLATION
VERTICAL STABILIZER
TAIL ROTOR
TRANSMISSION
TAILBOOM
AFT SECTION
INSTALLATION
TAIL ROTOR
ASSEMBLY
FLIGHT CONTROL
INSTALLATION
ENGINE
INSTALLATION
FORWARD SECTION MAIN TRANSMISSION AND

INSTALLATION POWER TRAIN
ENGINE ACCESS DOOR ASSEMBLY
CARGO DOOR ASSEMBLY
LOWER SECTION INSTALLATION
PILOT DOOR
ASSEMBLY
LANDING GEAR
369D/E/FF HELICOPTER
G010001A
Figure 1. Helicopter Major Components (Sheet 1 of 3)
Page 2
Revision 23 010000
MAINTENANCE MANUAL
VERTICAL STABILIZER ASSEMBLY
MAIN ROTOR INSTALLATION
SAS CONTROL ACTUATOR
STATOR
TAILBOOM
ASSEMBLY
AFT SECTION
INSTALLATION
FAN
GEARBOX
FLIGHT CONTROLS
INSTALLATION
FORWARD SECTION
INSTALLATION
MAIN TRANS-
MISSION
ENGINE
INSTALLATION
ENGINE ACCESS
DOOR ASSEMBLY
CARGO DOOR ASSEMBLY
LOWER SECTION INSTALLATION
PILOT DOOR
ASSEMBLY
LANDING GEAR
500N HELICOPTER
G010003
Page 3
010000 Revision 23
MAINTENANCE MANUAL
6BLADED MAIN ROTOR

INSTALLATION
FAN FAN
GEARBOX
MAIN TRANSMIS-
SION
FLIGHT CONTROLS HORIZONTAL

INSTALLATION STABILIZER
MID DOOR
ASSEMBLY
STATOR
AFT DOOR
ASSEMBLY
TAILBOOM
ASSEMBLY
VERTICAL STABILIZER
ENGINE ASSEMBLY
INSTALLATION
AFT SECTION
INSTALLATION
ENGINE ACCESS
DOOR ASSEMBLY
LANDING GEAR
FORWARD SECTION
INSTALLATION
PILOT DOOR
ASSEMBLY
LOWER SECTION
INSTALLATION
600N HELICOPTER
6G01001A
Page 4
Revision 23 010000
MAINTENANCE MANUAL
The fixed skid landing gear is attached to the handbooks and other published documents by
fuselage at 12 points. Fairings cover the struts their titles and/or identifying numbers. These
from the fuselage to the skids. Nitrogen documents are the primary servicing, mainte-
charged dampers between the struts and nance and repair information file for vendor
structure cushion landing loads. supplied helicopter components.
4. Scope
5. ATA Numbering System and Format
MDHI maintenance manuals provide system
descriptions, servicing and maintenance This MDHI Maintenance Manual and asso-
procedures, periodic and special inspections, ciated MDHI manuals are prepared in general
overhaul schedules, limited life component compliance with Air Transport Association
replacement schedules, and weight and Specification for Manufacturers Technical
balance calculations. Data (ATA100).
This manual is one of a group of publications
that form the information file for the helicop- The uniform numbering system established by
ter. The maintenance and inspection proce- ATA100 is used. This numbering system
dures are to be used for the 369D/E/FF provides a means for dividing material into
500/600N helicopters only. Study the contents Chapter, Section, Subject and Page. The
to gain an understanding of the arrangement number is composed of three elements, which
and use of this and associated manuals before consist of two digits each (Ref. Figure 2). The
working on the aircraft. chapter and section elements (subassembly
10, 20, 30, etc.) are assigned by ATA100.
Table 201, Related Publications and Direc- Subject/Unit element numbers are assigned by
tives, lists vendor/supplier manuals, catalogs, MDHI.
2ND ELEMENT
1ST ELEMENT 3RD ELEMENT
32 10 10
CHAPTER/SYSTEM LANDING GEAR SUBJECT/UNIT LANDING

SYSTEM GEAR
SECTION/SUBASSEMBLY LANDING GEAR
Figure 2. ATA Numbering System
Page 5
010000 Revision 26
MAINTENANCE MANUAL
6. Division of Subject Matter 8. Figure and Table Numbering

This Maintenance Manual is contained in two Illustrations and tables use the same number-
books. ing as the page block in which they appear. For
example, Figure 202 would be the second
CSPHMI2 contains general mechanical figure in a Maintenance Practices section.
maintenance data. When referring to a figure or table within the
same section, it is referenced as follows; (Ref.
CSPHMI3 contains maintenance data on Figure 202). When referring to a figure or
instruments, electrical and avionics. table within another section, it is referenced as
follows; (Ref. Table 1, 910000).
7. Page Number Blocks
9. Associated MDHI Manuals
Page number blocks used for each Section in
the Maintenance Manual logically arrange the Information beyond the scope of the Mainte-
material as follows: nance Manual may be found in these basic
associated manuals which are prepared as
NOTE: separate publications but should always be
D Maintenance Practices consists of either a kept and used with this manual:
brief subtopic or a combination of the fol- CSPIPC4, Illustrated Parts Catalog.
lowing subtopics: Servicing, Removal/Ins-
CSPCOM5, Component Overhaul Manual.
tallation, Adjustment/Test, Inspection/
Check, Cleaning/Painting and Approved CSPSRM6, Structural Repair Manual.
Repairs. Two methods are used for num- A. Illustrated Parts Catalog
bering maintenance practices page
blocks: (CSPIPC4) Illustrated Parts Catalog for
D If a single subtopic or all subtopics under Models 369D/E/FF 500/600N
Maintenance Practices are brief, they are (CSPD7) Illustrated Structures Catalog for
combined into one topic. All such topics Model 369D and
are numbered within page number block (CSPISC7) Illustrated Structures Catalog
201 300. for Models 369E/FF 500N provide, with text
and illustrations, a complete definition of all
D If individual subtopics become so lengthy repair parts and spare items available for the
that a combination would require numer- helicopter. Use the (IPC) only for the purpose
ous pages, each topic is broken out. Page of parts procurement.
number blocks accordingly are as follows:
B. Component Overhaul Manual (Overhaul
Description and Operation . . . . . . . . . . . . . . . . 1 Data)
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . 101 The COM contains overhaul instructions for
major components such as the main transmis-
Maintenance Practices . . . . . . . . . . . . . . . . . 201 sion, tail rotor transmission, overrunning
clutch, etc. When components must be
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 removed from service for overhaul, refer to the
COM and/or contact the appropriate manufac-
Removal/Installation . . . . . . . . . . . . . . . . . . . 401 turer or their field service representative for
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . 501 desired publication information (Ref. Table
201).
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . 601 C. Structural Repair Manual
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . 701 The CSPSRM6, SRM contains illustrated
helicopter structural maintenance and repair
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 information.
Initial Installation . . . . . . . . . . . . . . . . . . . . . 901 10. Engine Data
Each page bears an effective date, either that The Model 250 Series gas turbine engines are
of original issue or of the latest revision. manufactured by the Allison Engine Company
Page 6
Revision 26 010000
MAINTENANCE MANUAL
Inc.. Refer to the applicable Allison Engine (b). Blue Border Notices: The blue border
Repair and Maintenance Manual and the notices are not mandatory and can be
Illustrated Parts Catalog supplied with the accomplished at the owner/operators
engine for specific engine maintenance discretion. When instructed, these
information (Ref. Table 201, Related Publica- notices may require a record of
tions and Directives). Fault isolation and accomplishment. These notices deal
maintenance procedures for the helicopter/en- with noncritical or optional items
gine interface systems are in divisions only.
specified by the index.
(c). Service Bulletins: The Service
Bulletin deal with critical items that
11. MDHI Publications Changes and must be corrected. These bulletins
Revisions are mandatory and require a record
of accomplishment. They may be
Changes in the helicopter, equipment, mainte- reoccurring (flighttime or calendar)
nance practices, procedures and additional or onetime only bulletins. The
information developed by experience affect service bulletin replaces the red
manual content. To ensure that MDHI border notice.
manuals continue to reflect current changes,
revised information is provided by one or more (d). Technical Bulletin: The Technical
of the following communications: Bulletins are not mandatory and can
be accomplished at the owner/opera-
A. Revision tors discretion. When instructed,
these bulletins may require a record
Alteration of portions of the manual by the of accomplishment. These bulletins
replacement, addition and/or deletion of pages deal with noncritical or optional
is accomplished by revision. The List of items only. the technical bulletin
Effective pages (LOEP) that accompany each replaces the blue border notice.
revision identifies all affected pages. Such (e). For a complete listing and explana-
pages should be removed from the manual and tion of current and cancelled notices,
destroyed. Added or replaced pages should be refer to Service Information Notices
inserted and checked against the LOEP. Index.
(2). Service Information Letters are strictly
B. Reprint
information only. They may inform the
owner/operator of options available,
When large numbers of changes are involved,
upcoming notices, bulletins, warranty/
the manual is reprinted to include all prior
repair changes, etc.
revisions.
12. Application of Warnings, Cautions and
C. Service Information Notices and Letters Notes
Throughout this manual, and associated
Service information is to be considered as part
manuals, Warnings, Cautions and Notes are
of the manual.
used to emphasize instructions or information
considered to be unusual or critical.
(1). Service Information Notices and
Bulletins are broken into two categories WARNING and CAUTION statements are
as follows: always placed before the information or
instructions to which they apply.
(a). Red Border Notices: The red border
A NOTE may appear in the text either before
notices deal with critical items that
or after instructions to which it applies,
must be corrected. These notices are
depending on the relative significance of the
mandatory and require a record of
information.
accomplishment. They may be
reoccurring (flighttime or calendar) The conditions that warrant use of Warnings,
or onetime only notices. Cautions and Notes are defined as follows:
Page 7
010000 Revision 29
MAINTENANCE MANUAL
Operating procedures and 13. Service and Operations Report Form 1601
WARNING practices which, if not strict-
ly observed, may result in personal in- MDHI Service and Operations Report Form
jury, or loss of life. 1601 may be used to report to MD Helicopters,
Inc. in detail any service difficulties encoun-
tered with any MDHI helicopter. Use of the
Operating procedures and prac-
CAUTION tices which, if not strictly ob-
form is encouraged and recommended to
enable MDHI to provide owners and operators
served, may result in damage to or destruc- improved service, support and product
tion of equipment. improvements. The form also serves as a
convenient detailed record for owners and
NOTE: An operating procedure or condition operators. Copies of the form may be procured
that is essential to highlight. by contacting the Product Support Dept.
Page 8
Revision 28 010000
MAINTENANCE MANUAL
INTRODUCTION
MAINTENANCE PRACTICES
1. Maintenance and Operational Check Replace components that exhibit damage or
Requirements and Precautions wear beyond tolerances, or that negatively
affect the proper function or integrity of an
All helicopter maintenance is to comply with assembly.
the following requirements and precautions.
A. Pilots or Rotorcraft Flight Manual 3. Maintenance Information Requests
Maintenance checks requiring helicopter Address all questions regarding 369D/E/FF

operation must be performed in accordance 500/600N helicopter maintenance to the MDHI
with requirements and limitations specified in Field Service Representative assigned to the
the applicable MDHI Flight Manual (PFM or geographical area in which the helicopter is
RFM) and all applicable Optional Equipment being operated. Should there be no factory
Supplements. representative in the area, contact Product
Support Dept., Technical Publications, Mesa,
B. Operational Checks Arizona. If the item in question is vendor
After maintenance, modification, disassembly, supplied; i.e., engine, engine fuel control and
reassembly, replacement, cleaning, repair or governor, startergenerator, fuel cells, etc.,
installation; the affected parts, assemblies, contact the manufacturer directly to get
installations or systems shall be inspected and definitive answers to your questions (Ref.
an operational check will be performed prior to Table 201. Related Publications and Direc-
releasing the helicopter for flight (Ref. tives, which lists component manufacturers,
Maintenance Information Requests). suppliers and their addresses).
2. Inspections 4. Related Publications

Inspections specified in this manual are visual Publications and directives that form part of
inspections for cracks, corrosion, distortion, the information file for helicopter component
security and other obvious defects or damage. maintenance are listed in Table 201. Related
Visual inspections of fuel and oil system hoses, Publications and Directives.
tubes and fittings include checks for corrosion,
leakage and distortion. 5. Optional Equipment
Specific inspection requirements, procedures All optional equipment available for and
and wear tolerances may be provided in the usable on commercial model helicopters is
division text. Where inspection requirements listed in Table 202 Optional Equipment.
are not listed, inspections should be made per Contact MDHI for compatibility of mixing
Sections 051000 thru 055000. options.
Page 201
010000 Revision 23
MAINTENANCE MANUAL
Table 201. Related Publications and Directives

Component and Publication or
Manufacturer, or Source Publication Title Directive No.
General Information
Superintendent of Documents Acceptable Methods, Techniques and FAA AC No. 43.131A (1)
U.S. Government Printing Office Practices Aircraft Inspection and
Division of Public Documents Repair (GPO Catalog No. TD
Washington, D.C. 20402 428/2:972)
Advisory Circular Corrosion Control for FAA AC No. 434 (1)
Aircraft
IHS Aviation & Aerospace Nondestructive Testing Personnel NAS410
15 Inverness Way East Qualification and Certification
Englewood CO 80112
United States
Nondestructive Testing Personnel ASNTSNTTC1A

Qualification and Certification
Standard Terminology for ASTM E 1316
Nondestructive Examinations
Aerospace Industries Association of National Aerospace Standard NAS No. as applicable
America, Inc. (Title as applicable)
1725 De Sales Street, N.W.
Washington, 6, D.C.
Page 202
Revision 40 010000
MAINTENANCE MANUAL
Table 201. Related Publications and Directives (Cont)

MDHI Publications
MD Helicopters Inc. 369D Pilots Flight Manual (with CSPD1 (1)
M615G048 applicable Equipment Supplements)
4555 E. McDowell Rd.
369E Pilots Flight Manual (with CSPE1 (1)
Mesa, AZ 852159734
applicable Equipment Supplements)
Technical Publications Order Desk:
(480) 3466373 or (800) 3883378 369FF Pilots Flight Manual (with CSPFF1 (1)
FAX: (480) 3466809 applicable Equipment Supplements)
500N Pilots Flight Manual (with CSP520N1 (1)
600N Pilots Flight Manual (with CSP600NRFM1 (1)
Illustrated Parts Catalog (IPC), Model CSPIPC4 (1)
369D/E/F 500/600N
Basic Handbook of Maintenance CSPHMI2 (1)
Instructions (HMI2) Servicing and
Maintenance, Model 369D/E/F
500/600N
Basic Handbook of Maintenance CSPHMI3 (1)
Instructions (HMI3) InstrumentsElec-
tricalAvionics, Model 369D/E/F
500/600N
Component Overhaul Manual (COM), CSPDEF5 (1)
Model 369D/E/F 500/600N
Structural Repair Manual (SRM), Model CSPDEF6 (1)
369D/E/F 500N
Illustrated Structures Catalog (ISC), CSPD7 (1)
Model 369D
Illustrated Structures Catalog (ISC), CSPICS7 (1)
Model 369D/E/FF 500N
Corrosion Control Manual CSPA4
Battery
Marathon Battery Company Marathon Battery Instruction Manual BA89
Cold Spring, NY 10516 (REV 271)
Phone: (817) 7760650
(formerly Sonotone)
Page 203
010000 Revision 43
MAINTENANCE MANUAL

Engine
RollsRoyce Corporation Operation and Maintenance Manual, 10W2 (1)
P.O. BOX 420 Turboshaft Engine Model 250C20,
Indianapolis, IN 46206 USA C20B
Phone: 3172303774
Overhaul Manual, Turboshaft Engine 10W3 (1)
Fax: 3172306084
Model 250C20, C20B
email: indy.pubs.services@rolls
royce.com Illustrated Parts Catalog, Turboshaft 10W4 (1)
Engine Model 250C20, C20B
Installation Bulletin, Three Cubic Inch 1005 (1)
Accumulator for 250C20 Bendix Fuel
System
Operation and Maintenance Manual, GTP52322 (1)
Turboshaft Engine Model 250C20R/2
Overhaul Manual, Turboshaft Engine GTP52323 (1)
Model 250C20R/2
Illustrated Parts Catalog, Turboshaft GTP52324 (1)
Engine Model 250C20R/2
Operation and Maintenance Manual, 14W2 (1)
Turboshaft Engine Model 250C30
Overhaul Manual, Turboshaft Engine 14W3 (1)
Model 250C30
Illustrated Parts Catalog, Turboshaft 14W4 (1)
Engine Model 250C30
Operation and Maintenance Manual, CSP 21004 (1)
Turboshaft Engine Model 250C47M
Overhaul Manual, Turboshaft Engine CSP 22004 (1)
Model 250C47M
Illustrated Parts Catalog, Turboshaft CSP 23001 (1)
Engine Model 250C47M
StarterGenerator
Aircraft Parts Corporation Brush Seating APC Brushes in High SB150SG105
160 Finn Court Speed Starter Generators: MDHI Part
Farmingdale, NY 11735 Nos. 369A4550 and 369D28550
Phone: (516) 2493053
Overhaul Manual With Illustrated Parts TM 101
Datafax: (516) 2492577
Breakdown
TRW Aeronautical Systems Overhaul Instructions with Parts Call or write
Lucas Aerospace Breakdown, Models 23032010,
30 Van Nostrand Ave. 23032011, 23032020, 23032022,
Englewood, NJ 076314396 23032028, 23081001
Phone: (201) 5413250
Datafax: (201) 8941965
Fargo Manufacturing Co. Starter/Generator Cooling System STC No. SH907GL

2750 North Elston Ave. Supplemental Type Certificate
Chicago, Illinois 606447
Page 204
Revision 43 010000
MAINTENANCE MANUAL

Avionics Equipment
VHF/COMM Transceiver AVC110 VHF Communications IB8029004
RCA Aviation Equipment Dept. Transceiver Instruction Manual
11819 W. Olympic Blvd.
Los Angeles, CA 90064
VHF/NAV Receiver AVN210 Series Integrated Navigation IB96460

RCA Aviation Equipment Dept. Systems
University Sound of LTV Ling Altec, Inc. Operators Manual, SA250 and SA500
Oklahoma City, OK High Power Sound and Siren Systems
Operators Manual, Model 500 Super
High Power SolidState Amplifier and
Model RMC1 Remote Control
Automatic Direction Finder KR 85 Automatic Direction Finder 006004300
King Radio Corp. Installation Manual (has repair/overhaul
400 North Rogers Road information)
Olathe, KS
KR 86 Automatic Direction Finder 006508400
Maintenance/Overhaul Manual
KR 87 Automatic Direction Finder 006518400
NAV/COMM Receiver KX 155 NAV COMM Receiver 006517900
King Radio Corp. Maintenance/Overhaul Manual
NAV/COMM Transceiver and COMM KX 170A/B KX 175B NAV/COMM 006505300

Transceiver Transceiver and KY 195B
King Radio Corp. Communications Transceiver
COMM Transceiver KY 196 VHF COMM Transceiver 006516900

King Radio Corp. Maintenance/Overhaul Manual
Transponder KT 76A Transponder Maintenance/Ov- 006514300

King Radio Corp. erhaul Manual
VOR Indicator KI 201C VOR Indicator Maintenance/ 006505200

King Radio Corp. Overhaul Manual
KI 208 VOR Indicator Maintenance/Ov- 006513700
erhaul Manual
Audio Control Panel KMA 24H70/71 Audio Selector Panel 006558600
King Radio Corp. and Interphone System Maintenance/
Overhaul Manual
Page 205
010000 Revision 43
MAINTENANCE MANUAL

Automatic Direction Finder System ADF60 Automatic Direction Finder 523076618400611A
Collins General Aviation Division System Instruction Book
Avionics Group
CTLX2 Controls and CAD62 Control 523077249400111A
Rockwell International Corp.
Adaptor Instruction Book
Cedar Rapids, Iowa 52498
Collins Pro Line II Com/Nav/Pulse 523077271900211A
System Instruction Book
ALT55 Radio Altimeter System ALT55 Radio Altimeter System 5230766793
Collins General Aviation Division Instruction Book (Repair Manual
Publication Dept. 124212
400 Collins Rd. NE
Automatic Direction Finder System ADF650/650A Automatic Direction 523076620700411A
Collins General Aviation Division Finder System RCR650/650A
Receiver, ANT650 Antenna,
IND650/650A Indicator and ADA650
ADF to RMI Adaptor Instruction Book
COMM Transceiver VHF22B VHF COMM Transceiver 523077185400311A

Collins General Aviation Division Instruction Book
VHF251 Communications Transceiver 523076602900511A
and PWC150 Power Convertor
Instruction Book
NAV Receiver VIR351 Navigation Receiver, IND350 523076603000511A
Collins General Aviation Division Indicator, and PWC150 Power
Convertor Instruction Book
Transponder TDR950 Transponder Instruction Book 523076646400311A
Collins General Aviation Division
VHF AM/FM AN/ARC186(V) Collins VHF186 Transceiver Instruction 523077025100111A

Collins Government Avionics Division Book
Avionics & Missiles Group
Rockwell International
ICS Control Panel (C6533/ARC) A3011 Communication Control C465020 027

Andrea Radio Corp. Technical Manual Installation,
1140 45 Road Operation and Maintenance
Long Island City, NY 11101
COMM Transceiver ASB125, ASB60 SSB 99655

Sunair Electronics, Inc. Communications Equipment
3101 S.W. Third Avenue Maintenance Manual
Fort Lauderdale, FL 33315
Page 206
Revision 43 010000
MAINTENANCE MANUAL

Spilsbury & Tindall, Ltd. Instruction Manual, Stringer Model 65018
120 E. Cordova Street AC21 Mobile Antenna System
Vancouver 4, B.C. Canada
Fuel Cells
Uniroyal, Inc. Recommended Handling, Storage and FC147373
Engineered Systems Department Repair Procedures For NonSelfSeal-
Mishawaka, Indiana 46544 ing Flexible Fuel, Oil And Water Alcohol
Phone: (219) 2552181 Cells
Repair Procedure For SelfSealing Fuel RK1034
Cells
Engineered Fabrics Corp. Maintenance and Repair Manual, AP 368
Formerly: Loral Systems Group VITHANE\R Fuel Tanks,
669 Goodyear Street July 1988, ATA 281013
Rockmart, GA 301532417
Quick Cure Repair for Engineered AP 472
Phone: (404) 6847855
Fabrics Corp. Fuel Tanks of VITHANE\R
Construction,
March 1988, ATA 281015
Repair & Maintenance Manual, Bladder, AP 430
Self Sealing, & NonSelfSealing
Tanks, ARM Type Constructions,
April 1987, ATA 281016
Repair & Maintenance Manual, Bladder AP 2584
Fuel Tanks,
Nitrile Type Constructions,
June 1988, ATA 28101
Naval Publications & Forms Military Standard Inspection & MILSTD801A
Acceptance Standards For Propulsion
East:
Fluid Cells & Fittings
5801 Tabor Avenue
Philadelphia, PA 19120
Phone: (215) 6972179
Datafax: (215) 6975914
West:
Bookstore No. 10
ARCO Plaza, Level C
505 S. Flower Street
Phone: (213) 8945841
NOTE: Naval Publications personnel do not accept telephone orders. You must mail or FAX your written
request. There is no charge for the material.
Page 207
010000 Revision 43
MAINTENANCE MANUAL

Hoist Equipment
Hoist Winch Assembly BL1660012 Series 300 Pound HB136
Breeze Corporations, Inc. Capacity Hoist Operating Instructions
700 Liberty Avenue
BL1660040 Series Hoist Operating
Union, NJ 07083
Instructions
Use and Maintenance of Aircraft Hoist
Cable
Maintenance and Test Equipment
Model 177M6 Balancer ChadwickHelmuth Operation and Call or write
Model 8350 Balancer Service Instruction Handbooks are
Model 192A Balancer normally supplied with the equipment.
Model 8500 Balancer
Model 135M11 Strobex Blade Tracker
Model 135M12 Strobex Blade Tracker
must be used with Model 8500 Balancer
ChadwickHelmuth Co., Inc.
4601 N. Arden Drive
El Monte, CA 91731
Phone: (818) 5756161
Datafax: (818) 3504236
Landing Gear Equipment
Helicopter Float Assemblies Overhaul Manual with Illustrated Parts
GarrettAir Cruiser Company List, Helicopter Float Assemblies,
P.O. Box 180 Utility Floats 21D243681/2,
Belmar, NJ Emergency Floats D244845/6
Transmissions
Threaded Inserts Keenserts Catalog D
Newton Insert Co.
6500 Avalon Blvd.
Engine Oil Cooler

Harrison Radiator Division Service Overhaul Manual, Harrison HES66 77F
General Motors Corp. Aluminum Plate Type LiquidtoAir Revised Sept 30, 1973
Lockport, NY 14094 Coolers
Stewart Warner Corp.
Southwind Division
1514 Drover Street
Indianapolis, Indiana 46221
Phone: (317) 6328411
Page 208
Revision 43 010000
MAINTENANCE MANUAL

Scavenge Oil Filter
Filter Products Division Facet Kit No. 174105001 Installation E947, Rev. D 3/10/89 (1)
Facet Enterprises, Inc. and Service Manual Scavenge Lube Oil
8439 Triad Drive Filter
Greensboro, NC 27409
Phone: (919) 6684444
TWX 5109227331
Engine Intake Air Particle Separator

Pall Land Marine Corp. (PLM) Vortex Tube Repair PLMTM801
Formerly: Aircraft Porous Media (APM)
7070 Moon Lake Road
New Port Richey, FL 33552
Phone: (813) 8499999
Fuel Filter Pressure Switch

R.W. Jensen, Inc., Pressure Switch Repairs
215 Arena Street
El Segundo, CA 90245
Trim Actuators
CEF Industries, Inc., Trim Actuator Overhaul
Calco Division
TEL: (813) 4226419
FAX: (813) 4212069
Searchlight
Alexair SX Nightsun Searchlight STC No. SH2288NM
25320 Bellanca Way (Spectrolab)
Torrance, CA 90505
Phone: (213) 3265222
NOTES:
(1) Publication should be maintained and treated as part of the primary information file for the helicopter.
Page 209
010000 Revision 43
MAINTENANCE MANUAL
Table 202. Optional Equipment List

Nomenclature Part Number 369D 369E 369FF 500N 600N
10 PARKING AND MOORING
M/R blade stowage rack 369D299913 X X X
21 ENVIRONMENTAL CONTROL SYSTEM
Heating system 369H90020 X X X X X
25 EQUIPMENT / FURNISHINGS
Seat assy. passenger compartment 369D290037 X
Litter kit (bubble doors and flat glass) 369H90011519 X X
Litter kit (W/O doors) 369H90011521 X X
Seat and belts (four on the floor) 369H90035 X X X X
Seat (mesh) 369H90040 X X X X
Hoist 369H90070 X X X X
Cargo hook 369H90072 X X X X X
Seat belt assembly (pilot, copilot) 369H6541 X
Shoulder harness and seat belt inertia reel 421099 X X X
Litter kit 369D290170 X X
Litter kit TAHH0001 X X X
Forward equipment tray 369D292200 X X X
26 FIRE PROTECTION
Fire extinguisher 369H90001 X X X X X
28 FUEL SYSTEM
Antiice fuel filter 369H90022 X X X
Airframe fuel filter 600N98110 X
Fuel tank, selfsealing 369H90029 X X X X
Drain, auxiliary engine fuel filter 369H92255 X
32 LANDING GEAR
Extended landing gear 369D290007 X X X X
Extended landing gear 600N6000 X
Step assembly, extended landing gear 600N6501 X
Utility floats 369D290086 X X
Emergency floats 369D290121 X X X X
Ground handling wheels (pneumatic) 369H90045 X X X X
Ground handling wheels (compact) 369H90126 X X X X
Float lamp assembly 369D292032 X X X X
Landing gear kit, winterized 369D290010 X X X X
Landing gear kit, midtemp 369D290012 X X X X
Metal landing gear fairings SA4344 X
Page 210
Revision 43 010000
MAINTENANCE MANUAL
Table 202. Optional Equipment List (Cont)

52 DOORS
Door (litter) 369H90085 X
53 FUSELAGE
Magnesiumtoaluminum conversion kit M30251501 X X X X
Clear windshield kit 369H90026 X
Comfort window 369D290026 X X X
Side window (fwd extended canopy) 369D292491 X X
Upper and lower windshield (Heliplex) SH7443SW X X X
Window, crew (Heliplex) SH7404SW X X X
Window, passenger (Heliplex) SH7405SW X X X
63 TRANSMISSION AND DRIVE SYSTEM
M/R transmission oil cooler drain 369D290120 X
Rotor brake 369H90123 X X X X X
64 ANTITORQUE ASSEMBLY
4Bladed tail rotor drive system 369D292500 X X
67 FLIGHT CONTROLS
Dual controls, L/H command 369H90033 X X X X X
Cyclic stick grip kit 369H90129 X X X X
Right hand command kit 369D297001 X X X X X
Yaw Stability Augmentation System 600N97300 X
71 POWER PLANT
Engine air inlet deflector kit 369D292044 X X
Mist eliminator access panel 369D290270 X X X
Foriegn particle diverter kit 369D292045 X X
250C20R/2 conversion kit 369D298000 X X
Particle separator 369H90148 X X X X
Particle separator filter 600N90148 X
Particle separator 600N90125 X
Particle separator fairing 600N90128 X
Engine compressor water wash kit 369H92537 X X X X X
Mist eliminator 369D290125 X
C30 maintenance fuel pump kit 369D298100 X X
StarterGenerator cooling system A1400185 SH907GL X
95 INSTRUMENTS
IVSI 369D294508 X X X
Heated pitot tube 369H90034 X X X X
Heated pitot tube 600N90034 X
Page 211
010000 Revision 43
MAINTENANCE MANUAL

Attitude gyro indicator 369H90038 X X X X
AIM attitude gyro (5101BL) 600N96501 X
Directional gyro indicator 369H90039 X X X X
AIM 200 directional gyro (200DCL) 600N96502 X
AIM 205 directional gyro (2051BL) 600N96503 X
Instantaneous vertical speed indicator 369H90044 X X X
Vertical speed indicator 600N96523 X
Instantaneous vertical speed indicator 600N96524 X
Auto direction finder (KR85) 369H90067 X
Auto direction finder (Collins ADF650A) 369D24165 X X
Auto direction finder (KR87) 600N96508 X
Compass system (KCS55A) 600N96528 X
Altimeter indicator (millibar scale) 369H90124 X X X
Radar altimeter 600N96506 X
Encoding altimeter (United 5035) 600N96522 X
AIM turn/bank indicator (TS4001AL) 600N96504 X
Digital/Analog TOT indicator 369D294509 X X X
96 ELECTRICAL POWER
17AH nicad battery 369D290011 X X X X
Dualstarting kit M30306 X
FWD battery 369D222505 X
13AH nicad battery 369D24296 X
97 AVIONICS
Transponder, Mode S (KT70) 600N96509 X
Transponder (KT76A) 369H90073 X
Transponder (King KT76A) 369D24163 X X
Transponder (Collins TDR950) 369H90009 X
Transponder (Collins TDR950) 369D24166 X X
Transponder, Mode A/C (KT76A) 600N96511 X
GPS International (KLN 90B) 600N96507 X
NAV/COM (Collins) 369H90007 X
NAV/COM transceiver (KX170A) 369H90071 X
NAV/COM transceiver (KX155) 369D24147 X X
NAV/COM transceiver (KX155) 600N96512 X
NAV/COM transceiver (King KX1756) 369D24162 X X
NAV/COM (Collins VHF251 and VIR351) 369D24164 X X
Transceiver (VHF22B) 369D24322 X
Page 212
Revision 43 010000
MAINTENANCE MANUAL

Comm. receiver (Bendix/King KY196) 369D24167 X X
Comm. receiver (KY196A30) 600N96513 X
ADF (Collins RCR650) 369H90008 X
ADF (King KR87) 369D24161 X X
ADF (Collins 60A) 369D24333 X
ICS system 369H90068 X
ICS system 369D24118 X X X X
NAT AA82/AA83 stereo ICS 600N96505 X
Copilot foot switch 600N96526 X
Rear seat transmit switch 600N96527 X
Radio (ASB/125/60) 369H90144 X
Headset, microphone assembly 369H92042 X X X X
Switch and jack assembly, intercom 369H92492 X X X X
Headset microphone H1056 X X X X
Harness assembly (VHF22B) 369D24321 X
Instrument and electrical (R/H command) 369D24175 X
Sterio audio control 600N96529 X
Audio control panel (KMA24H) 600N96514 X
Middle seat wire harness 600N96515 X
Collective Hobbs 600N96525 X
Page 213
010000 Revision 43
MAINTENANCE MANUAL
Page 214
Revision 43 010000
MAINTENANCE MANUAL
Chapter
04
Airworthiness
Limitations
MAINTENANCE MANUAL
TABLE OF CONTENTS
040000 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Component Mandatory Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Component Mandatory Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Retirement Index Number (RIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Torque Event (TE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. External Lift and Torque Event (TE) Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1. Airworthiness Limitations Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
040001 Airworthiness Limitations Supplements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. UK CAA Airworthiness Limitations Section Supplement . . . . . . . . . . . . . . . . . . . . . . 1
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
040000
Airworthiness
Limitations
MAINTENANCE MANUAL

MAINTENANCE MANUAL
AIRWORTHINESS LIMITATIONS
Type Certificate No. H3WE
FAA Approved Airworthiness Limitations for MD Helicopters, Inc., Models 369D/E/F/FF and
500/600N.
1. General
The Airworthiness Limitations section is FAA approved and specifies maintenance required under
Code of Federal Regulations (CFR), Title 14, Federal Aviation Regulation (FAR), Part 43.16 and
91.403 unless an alternative program has been FAA approved.
REVISION: DATE FAA SIGNATURE AND DATE

Original Issue: October 31, 1990 Not FAA approved
Revision 1: March 29, 1991 Not FAA approved this revision
Revision 2: May 10, 1991
TR 91001 August 12, 1991
Revision 3: September 9, 1991
TR 91002 November 5, 1991
Revision 4: January 20, 1992
TR 92004 May 20, 1992
Revision 5: August 24, 1992
TR 92005 November 20, 1992
Revision 6: December 21, 1992
Revision 7: June 1, 1993 Section 040000 Not Affected This Revision
TR 93002 May 27, 1993
Revision 8: July 23, 1993
TR 94001 January 21, 1994
Revision 9: April 22, 1994
Revision 10: September 26, 1994 Section 040000 Not Affected This Revision
TR 94002 October 24, 1994
Page 1
FAA APPROVED 040000 Revision 42
MAINTENANCE MANUAL
Revision 11: January 18, 1995
Revision 12: October 6, 1995 Section 040000 Not Affected This Revision
TR 96002: April 24, 1996
Revision 13: May 31, 1996
Revision 14: September 13, 1996
Revision 15: November 15, 1996 Section 040000 Not Affected This Revision
Revision 16: January 6, 1997 Section 040000 Not Affected This Revision
Revision 17: February 24, 1997
TR 97001: July 2, 1997
TR 97002: August 19, 1997
Section 040000 Not Affected This Revision

Revision 18: October 17, 1997
T/R 97001 and 97002 Previously Signed
Revision 19: December 16, 1997
TR 98001: March 25, 1998

Revision 20: June 1, 1998
T/R 98001 Previously Signed
TR 98002: June 22, 1998
TR 98003: 3 August 1998

Revision 21: 24 August 1998
Revision 22: 10 March 1999 Section 040000 Not Affected This Revision
Revision 23: 1 June 1999 Section 040000 Not Affected This Revision
Revision 24: 7 December 1999
Revision 25: 28 April 2000 Section 040000 Not Affected This Revision
Revision 27: 9 October 2000 Section 040000 Not Affected This Revision
Revision 28: 30 November 2000 Section 040000 Not Affected This Revision
Page 2
Revision 42 040000 FAA APPROVED
MAINTENANCE MANUAL
Revision 29: 11 May 2001
Revision 30: 11 July 2001 Section 040000 Not Affected This Revision
TR 01001: 10 August 2001

Revision 31: 5 November 2001
TR 02002: 30 January 2002
Revision 32: 18 March 2002
Revision 33: 24 June 2002
TR 03001: 18 June 2003
TR 03002: 25 June 2003

TR 03003: 30 September 2003
TR 03004: 17 December 2003

Revision 35: 20 May 2004
TR 04001: 28 May 2004
Revision 36: 11 November 2004
Revision 37: 13 December 2005 Section 040000 Not Affected This Revision
TR 05002: 16 December 2005

Revision 38: 25 April 2006
Page 3
MAINTENANCE MANUAL
TR 06001: 05 July 2006
Revision 39: 10 April 2007 Section 040000 Not Affected This Revision
TR 07001: 11 April 2007 Section 040000 Not Affected This Revision
Revision 41: 03 March 2008
TR 08001 14 March 2008
TR 08002 07 November 2008

Revision 42:
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MAINTENANCE MANUAL
AIRWORTHINESS LIMITATIONS
2. Component Mandatory Replacement number, component time and current
helicopter hours are recorded in the Log
The Airworthiness Limitation Replacement Book and component log for the
Schedule specifies the mandatory replacement helicopter. Whether the lifelimited
time, structural inspection interval and related part is new or used, the remaining
structural inspection procedures approved per number of useful life hours and pre-
the certificate basis of the Type Certificate vious inspection time, if applicable, for
Data Sheet No. H3WE and CAR 6 (6.250, the part is added to the existing
6.251) and CFR 27.571 for models 500/600N helicopter time. The total helicopter
unique components only. At the listed finite hours obtained then denotes the
life, components or assemblies must be subsequent time at which the part must
removed from the helicopter and permanently be removed from the helicopter or
retired from service. At the listed inspection inspected.
interval, the components or assemblies must
be inspected in accordance with the Handbook (4). If a lifelimited part, is part of an
of Maintenance Instructions (HMI). The title assembly, the assembly must be
of the task and section of the HMI are referred removed from the helicopter when the
to which provide the inspection procedures and time expires. The assembly may be
criteria. overhauled and restored to maximum
number of hours of useful life by
NOTE: Refer to CFR Part 43.10 for latest reinstalling new lifelimited parts plus
quirements for the removal, installation, all other parts specified in the overhaul
storage and disposition of lifelimited parts. instructions (Refer to Component
Overhaul Manual).
(1). A lifelimited part is a physical
component of the helicopter to which a (5). If interchanged between different model
maximum number of allowable operat- helicopters (for instance, Model 369D to
ing hours or cycles are assigned. 369FF or vice versa), any component
Certain assemblies and components on having a limited life or overhaul
the helicopter have a limited life schedule must be restricted to the
established by MDHI and approved by lowest service life or TBO schedule
FAA Engineering. For example, a part indicated for the helicopter models and
with an assigned limit of 1000 hours, serial numbers affected.
may accumulate 1000 hours of opera- (6). Refer to the appropriate Allison
tion in service. Upon completion of the Operation and Maintenance Manual for
1000 hours of operation, useful life of engine component replacement require-
the part is ended. The finitelife ments.
assigned to different parts varies
according to engineering fatigue tests, 3. Component Mandatory Inspections
part experience, etc. The parts listed in
this section must be removed from the Some components with mandatory inspection
helicopter at the finitelife indicated intervals require inspections to be completed
and identified as to its expired life (Ref, in accordance with procedures detailed in
Table 1, Note (1)). other sections of this maintenance manual.
The appropriate inspection procedures are
(2). All parts not having an assigned life or referenced in the Notes flagged to each
stated to be of unlimited life, have a life component to be inspected. All maintenance
of not less than 20,000 hours. manual procedures which are referenced in the
FAA Approved Airworthiness Limitations
(3). When a lifelimited part or an assem- Component Mandatory Replacement Schedule
bly that incorporates a lifelimited part are FAA approved procedures which cannot be
is installed on a new or used helicopter, changed without FAA review and approval of
the nomenclature, part number, serial the proposed changes.
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MAINTENANCE MANUAL
4. Retirement Index Number (RIN) For external lift operators, an external

load is recorded as two (2) TEs (pick
(1). A Retirement Index Number (RIN) is a up and dropoff).
number that accounts for different
usage spectra in assigning the retire- Hover taxi with no external load will
ment time for a component. typically result in no TEs.
The RIN is calculated as the sum of an 6. External Lift and Torque Event (TE)
adjustment factor times flight hours Requirements
plus another adjustment factor times
Torque Events. The 369D/E/F/FF 500/600N helicopters are
multiuse helicopters. If the helicopter is used
When a component reaches 1,000,000 primarily for external lifts or training flights
RINs, it has reached its maximum life (high TE flights), there may be a reduction in
and is to be scrapped. inspection intervals of some components.
For safe operation of the heli-

5. Torque Event (TE) CAUTION copter, TEs must be recorded in
the Rotorcraft Log Book. Each external lift
A Torque Event (TE) is defined as: will be recorded as two (2) TEs.
The transition to a hover from forward (1). Determine the number of TEs and
flight. external lifts the helicopter accumu-
lates per hour of flight time.
Any external lift operation.
(2). Record all TEs in Rotorcraft Log Book
NOTE: An external lift can either be on the car- and continue to record all TEs.
go hook, external hoist or in external bas-
kets. (3). Perform required TE inspections.
Table 1. Airworthiness Limitations Schedule

Finite Life Mandatory
Component Part Number
Model Hours Inspection
(1) (2)
(1) Hours
Main Rotor System
Blade assembly, main rotor 369D/E(5)(6) 369D21100 3530 (37) 25 (11)(20)
369D21100516 3530 (37) 100 (20)
369D21100517 2500 (31) 25 (22)
369D21100517 3530 (37) 100 (20)
369D21100523 4000 (37) 100 (20)
369D21120501 3530 (37) 100 (20)
369D21120503 3530 (37) 100 (20)
369D21120505 3530 (37) 100 (20)
369F/FF (6) 369D21102 3430 (37) 25 (11)(20)
369D21102503 3430 (37) 100 (20)
369D21102517 2500 (31) 25 (22)
369D21102517 3430 (37) 100 (20)
369D21102523 4000 (37) 100 (20)
369D21121501 3430 (37) 100 (20)
369D21121503 3430 (37) 100 (20)
369D21121505 3430 (37) 100 (20)
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MAINTENANCE MANUAL
Table 1. Airworthiness Limitations Schedule (Cont.)

(1) (2)
(1) Hours
Blade assembly, main rotor 500N (6) 369D21102503 3430 (37) 100 (20)
369D21102517 2500 (31) 25 (22)
369D21102517 3430 (37) 100 (20)
369D21102523 4000 (37) 100 (20)
369D21121501 3430 (37) 100 (20)
369D21121503 3430 (37) 100 (20)
369D21121505 3430 (37) 100 (20)
600N (6) 369D21102517 (21) 1900 (32)(37) 100 (20)
369D21102523 3200 (33)(37) 100 (20)
369D21121501 3200 (33)(37) 100 (20)
369D21121503 3200 (33)(37) 100 (20)
369D21121505 3200 (33)(37) 100 (20)
Folding pin, main rotor blade attach 369D/E/F/FF 369A1004 2850
369A10043 2850
369A10045 7600
500/600N 369A10045 7600
Hub subassembly, main rotor 369D/E/F/FF 369D21201 8900
500N
Pitch housing assembly, main rotor hub 369D 369D21300 9100
369D21300501 9100
369E/F/FF 369D21300501 9100
500N
Retention strap assembly, main rotor hub 369D 369D21210 2770 100 (4)
369D21210501 2770 100 (4)
369E/F/FF 369D21210501 2770 100 (4)
500/600N 369D21210501 2770 100 (4)
Bolt leadlag hub, main rotor 369D 369A1220 6120
369D/E/F/FF 369D21220 6120
500N
600N 369D21220 5400 (34)
Page 7
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Link assembly lead lag hub, main rotor 369D/E 369H1203BSC (39) 5762 25 (23)
369H120321 (39) 5762 25 (23)
369H120331 (39) 5762 25 (11)
369H120351 (39) 11080
369H120353 (40) 11080
369H120361 (39) 11080
369F/FF 369H120321 (39) 5762 25 (23)
369H120331 (39) 5762 25 (11)
369H120351 (39) 11080
369H120353 (40) 11080
369H120361 (39) 11080
500N 369H120351 (39) 11080
369H120353 (40) 11080
369H120361 (39) 11080
600N 369H120351 (39) 11080
369H120353 (40) 11080
Lead lag damper main rotor 369D 369D21400501 6060
M50452 On Cond. (16)
369D/E/F/FF 369D21400503 On Cond. (16)
500/600N
Drive shaft, main rotor 369D/E 369D25510 5020 300 (8)
369F/FF 369D25510 3675 300 (8)
500N 369D2551021 3260 300 (15)
369D/E 369F5510 (42)
369F/FF 369F5510 (42)
500N 369F5510 (42)
600N 600N5510 14000 (35)
Mast assembly, main rotor 369D/E/F/FF 369D22014 10450
500N
600N 369D22014 3500
Page 8
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Drive Shafts, Couplings and Clutches
Drive shaft, main rotor transmission 369D/E/F 369A5510 3790
Coupling, main transmission drive shaft 369D/E/F/FF 369H5660 4300
500N 369H5660 3200
Overrunning clutch assembly 369D/E/F/FF 369F5450501 On Cond. 100 (24)
500/600N
Sprag assembly, overrunning clutch 369D/E/F/FF 369A5364 (3) 300 (10)
369D25351
500N 369D25351 (3) 300 (10)
369D/E/F/FF 369F5456 (3) 300 (17)
500/600N
Drive shaft, fan 500N 500N5200 2620
600N 500N5200 1200 (36)
Drive shaft, tail rotor 369D/E 369D25518 13900
369F/FF 369DSK15211 13900
369D25518503 14610
Coupling tail rotor drive shaft (Bendix) 369D/E/F 369A5501 4980
(NOTE: Not certified on 369FF Model) (9) 369H92564 (7) 4980
AntiTorque System
Gearshaft assembly, tail rotor input 369D/E 369D25434 12000
369F/FF 369D25434 3365
Gearshaft, tail rotor output pinion 369D/E/F/FF 369D25430 7290
Blade assembly, tail rotor 369D/E 369D21613 5200
369D2161311 5140
369D2161331 5140
369D2161341 5140
369D2161351 5140
369D2161361 5140
369D2161371 5140
369D21640501 (38) 400
369D21640503 (38) 5140
369D21640505 (38) 5140
369D21640507 (38) 5140
369F/FF 369D21606 5140
369D21642501 (38) 400
369D21642503 (38) 5140
369D21642505 (38) 5140
369D21642507 (38) 5140
Page 9
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Blade assembly, tail rotor 369D/E 369D21615 10000
(optional 4blade) 369D21641501 (38) 400
369D21641503 (38) 10000
369D21641505 (38) 10000
369D21641507 (38) 10000
Hub, tail rotor 369D/E/F/FF 369A1725 3450
Retention strap assembly, tail rotor 369D/E/F 369A1706 5100
369FF 369A1706507 5100
369A1706509 5100
Blade assembly, NOTAR fan 500N 500N531015 7500
500N531019 7500
600N 500N531019 12500
Hub, fan 500N 500N53527 7500
500N53529 7500
600N 500N53529 7500
TensionTorsion Strap, NOTAR 500N 500N53115 (43)(44)
600N
Shaft, NOTAR fan support 600N 500N535713 4000
Pitch plate assembly 500/600N 500N53637 7500
Tube assembly, fan pitch 500N 500N71133 600 (18)
Rotating cone assembly 500N 500N37401 10000
500N374041 10000
Rotating cone assembly 600N 500N374061 10000
Tailboom
Bolts, tailboom attach 369D/E/F/FF MS2125006014 21950
Tailboom assembly 369D/E 369D23500 10300
369F/FF 369D23500507 10300
500N 500N350019 10000 100 (14)
500N350029 10000
500N3500501 10000
500N3600501 10000 100 (14)
600N 600N3500503 2500 (25)
600N3500505 5900
600N3500507 1000
600N3500509 6000 (19)
600N3500511 6000 (19)
600N3500513 2500 (25)
600N3500515 5900
600N3500517 1000
Empennage fittings 600N 500N35307/8 On Cond. 100 (26)
500N35309/10 On Cond. 100 (26)
Page 10
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Vertical stabilizer assembly 369D/E 369D23600 12700
369F/FF 369D23600505 3388
Torque tube, horizontal stabilizer 500N 500N39505 5000
600N 500N39507 3000
600N3950 1000 (19)
Horizontal stabilizer assembly 369D (12) 369D23601 7700
369E (12) 421087505 7700
421087905 (13) 7700
369F/FF (12) 421087503 7700
421087903 7700
600N 500N391025 10000 (19)
500N391027 10000 (19)
Controls
Longitudinal idler bellcrank assembly 369D 369A7301 6500
369A7301501 6500
369E/F/FF 369A7301501 6500
500N 369A7301501 2870
Idler assembly, longitudinal pitch mixer 369D/E/F/FF 369A7603 13600
500N 369A7603 6050
Longitudinal control rod 500N 369A701113 7740
369A701115 7740
Socket, cyclic stick 600N 369A7141 1000 8 (27)
Cyclic tube assembly 600N 369D27132503 1200 8 (27)
Housing, collective stick 600N 369A7347 450
Tube, collective pitch control 600N 369A7348 400
Tube assembly, collective pitch (pilot) 600N 369H73543 600
Socket, cyclic stick 600N 369A7802 1000 8 (27)
Tube, collective pitch (copilot) 600N 369A7809 1800
Housing, collective stick 600N 369A7820 450
Housing, collective stick 600N 369H7837 450
Tube assembly, collective pitch (copilot) 600N 369H78383 1000
Fuselage Sta. 75 controls support bracket 600N 369N260811 6000 (41)
600N26089 Unlimited
Airframe
Landing gear brace 600N 600N601017/19 5900 (28)
Landing gear strut 600N 600N60227/8 696 (29)
Landing gear foot 600N 600N60433 3900 (30)
Page 11
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Floats
Squib cartridge, used on Emergency float 369D/E/F/FF 125521 5 years
kit 369D2924735, 6, 9, 10, 11, 12 500N (Holex, Inc.)
NOTE: Life is based from original date of 281993 5 years
manufacture. (Walter Kidde)
127541 5 years
(Holex, Inc.)
5003527 5 years
(Tavco)
Stabilizer support, utility float 369D/E 369D292036 3190
369DSK66 3190
NOTES:
(1) Lifelimited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Lifelimited components removed at
retirement are to be mutilated/destroyed or conspicuously marked to prevent inadvertent return to service.
Parts are applicable only on models under which a service life is listed.
Lifelimited components cannot be altered or permanently marked in any manner without compromising
the part integrity. Part tagging or other record keeping system is required.
Related component records must be updated each time component is removed from service.
(2) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(3) With no cargo hook attached: No retirement life assigned (Ref. Sec. 051000, Component Overhaul or
Recommended Replacement Schedule).
With cargo hook attached and no separate log: 1800 hours.
With cargo hook attached and with separate log: 1800 hours of external load operating time when logged
separately.
(For 369D/E/F/FF helicopters with 369A5364 or 369D25351 sprag assembly, Refer to AD 901902.)
(4) Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 100hour intervals, or 25hour
intervals if 2 laminates (369D/E/F/FF 500N) or 1 laminate (600N) have failed in any one leg or tongue
area of any strap assembly. A single cracked laminate between the shoes at the outboard end of a strap
pack is cause for rejection of the hub assembly
369D/E/F/FF 500N: (Ref. Sec. 622000, Main Rotor Strap Pack Lamination Inspection).
600N: (Ref. Sec. 622060, Main Rotor Strap Pack Lamination Inspection).
(For 369D/E/F/FF helicopters, refer to AD 890201.)
(5) The 369D21100513, 515, 516, 517 and 523 main rotor blades are not interchangeable with any earlier
configuration blades (Basic, 505 or 509); however, the 505 and 509 blades are interchangeable and
the 513 and 515 blades are interchangeable. The 505 and 509 configuration blades may be modified
to the 513M configuration, which is fully compatible with the 513 blade. (For information concerning
modification, contact MDHI Customer Service Department.)
(6) For the 369D/E helicopters, the 369D21120501, 503 main rotor blade has all the same inspections and
interchangeability as the 369D21100517 main rotor blade.
For the 369F/FF 500N helicopters, the 369D21121501, 503 main rotor blade has all the same
inspections and interchangeability as the 369D21102517 main rotor blade.
For the 600N helicopters, the 369D21121501, 503 main rotor blade has all the same inspections and
interchangeability as the 369D21102523 main rotor blade.
(7) Used with 369H90123 Rotor Brake Kit.
Page 12
MAINTENANCE MANUAL
(8) Inspect main rotor drive shaft every 300 hours (Ref. Sec. 631000, Main Rotor Drive Shaft Inspection
(300 Hour)) (Reference AD 812601).
(9) Failsafe device, P/N 369D25530 bolt and 369D25531 socket, must be used at both ends of tail rotor
driveshaft in accordance with Tail Rotor Drive Shaft Installation with Bendix Couplings (Reference AD
862007).
(10) For helicopters equipped with a cargo hook, inspect overrunning clutch sprag assembly P/N 369D25351,
clutch inner race P/N 369A5353 and outer race 369A5352 every 300 hours (Ref. C.O.M., Sec. 631010,
Overrunning Clutch Sprag Inspection (300 Hour)). To establish time in service, either clutch total time with
hook attached or a separate and permanent log of external load operating time per CFR 91.417, may be
used.
(For 369D/E/F/FF helicopters with 369A5364 or 369D25351 sprag assembly, Refer to AD 901902.)
(11) Inspect main rotor blade root fittings and main rotor leadlag link assemblies every 25 hours in accordance
with Main Rotor Blade Upper and Lower Root Fitting Attach Lug and LeadLag Link Attach Lug Inspection
(25 Hour) and every 100 hours in accordance with Main Rotor Blade Upper and Lower Root, Fitting Attach
Lug and LeadLag Link Attach Lug Inspection (100 Hour) (Ref. Sec. 621000) (Reference AD 950313).
(12) Tip plates, tip weights (where applicable) and attaching hardware have no retirement life and may be
reused on replacement horizontal stabilizers.
(13) 421087903 and 905 require addition of tip plates, tip weights and attaching hardware before
installation.
(14) Inspect the three upper slot bridges for cracks (Ref. Sec. 052000).
(15) Inspect main rotor drive shaft every 300 hours (Ref. Sec. 631000, Main Rotor Drive Shaft Inspection
(300 Hour)).
(16) Inspect for deterioration every 600 hours up to a total time of 4200 hours and every 300 hours thereafter
until deterioration is sufficient to retire assembly
369D/E/FF 500N: (Ref. Sec. 622000, Main Rotor Damper and Attachments Inspection)
600N: (Ref. Sec. 622060, Main Rotor Damper and Attachments Inspection).
(17) For helicopters equipped with a cargo hook, inspect overrunning clutch sprag assembly P/N 369F5456,
clutch inner race P/N 369F5455 and outer race 369F5453 every 300 hours. To establish time in service,
either clutch total time with hook attached or a separate and permanent log of external load operating time
may be used.
(18) 500N711311 tube assembly, fan pitch is an OnCondition part and replaces the 500N71133 tube
assembly.
(19) Interim hours: life extension testing in progress.
(20) Inspect upper and lower blade root fittings every 100 hours in accordance with Main Rotor Blade Upper
and Lower Root, Fitting Attach Lug and LeadLag Link Attach Lug Inspection (100 Hour) (Ref. Sec.
621000)
(For 369D/E/F/FF 500N helicopters, Reference AD 961009).
(21) Main rotor blades, P/N 369D21102517 with S/N 1976 thru 2100, 2106 thru 2115 are not to be installed on
600N helicopter (Reference Service Bulletin SB600N007R2) (Reference AD 981526).
(22) Inspect main rotor blades with 600 or more hours of operation every 25 hours of helicopter operation with a
10X magnifying glass for cracking of the lower surface of the blade emanating from the root fitting and
doubler at the inboard end of the blade and to detect debonding between the blade root end fitting and
doubler if missing or cracked adhesive or paint is observed. (Reference Service Bulletins SB369D195R3,
SB369E088R3, SB369F075R3, SB500N015R3) (Reference AD 981526).
(23) Perform Main Rotor Blade Upper and Lower Root, Fitting Attach Lug and LeadLag Link Attach Lug
Inspection (25 Hour) up to a total time of 500 hours and every 15 hours thereafter and every 100 hours in
accordance with Main Rotor Blade Upper and Lower Root Fitting, Attach Lug and LeadLag Link Attach
Lug Inspection (100 Hour) (Ref. Sec. 621000) until retirement of 369H1203BSC and 21 LeadLag
Link Assembly. (Reference AD 950313).
(24) Inspect clutch retainer and bearing carrier for evidence of spinning and/or wear (Ref. Sec. 052020).
Page 13
MAINTENANCE MANUAL
(25) The 600N3500503 tailboom may be reworked to a 600N3500505 tailboom, and the 600N3500513
tailboom may be reworked to a 600N3500515 tailboom by modifying the attachment fittings to allsteel
fittings.
(26) (Ref. Sec. 052000) Using a flashlight and 10X magnifying glass, inspect horizontal stabilizer mounting
brackets for cracks (pay particular attention to the forward inboard legs) (Ref. Tailboom Inspection).
(27) Sockets must be inspected for cracks every eight hours after the initial 100 hour inspection.
(28) Log all landings: Brace life is limited to 35400 logged landings or 5900 hours flight time if landing are not
logged (assumed six landings per one hour of flight time).
(29) Log all landings: Strut life is limited to 4170 logged landings or 696 hours flight time if landing are not
(30) Log all landings: Foot life is limited to 23780 logged landings or 3900 hours flight time if landing are not
(31) The following main rotor blades have a finite life of 2,500 hours or 15,000 torque events*, whichever occurs
first;
P/N 369D21100517 with S/N H664, H665, H667, H669, H671, H672, H674, H676, H679, H680, H683 thru
H724, H726 thru H999 and J000 thru J039, J041 thru J055 and
P/N 369D21102517 with S/N 1976 thru 2100, 2106 thru 2115.
* TORQUE EVENT (TE) A TE is recorded for every transition from forward flight to a hover (Reference
Service Bulletins SB369D195R3, SB369E088R3, SB369F075R3, SB500N015R3).
(32) RIN = (200 x Hrs.) + (52 x TE).
(33) RIN = (160 x Hrs.) + (24 x TE).
(34) RIN = (153 x Hrs.) + (3 x TE).
(35) RIN = (50 x Hrs.) + (3 x TE).
(36) RIN = (768 x Hrs.) + (11 x TE).
(37) After accumulation of 750 flight hours and 13,720 TE, perform Main Rotor Blade Torque Event Inspection
(Ref. Sec. 621000) every 35 flight hours or 200 TEs (whichever occurs first).
(38) The 369D21640501, 503, 505, 507 tail rotor blades are twoway interchangeable with the 369D21613
tail rotor blades in sets of two only.
The 369D21641501, 503, 505, 507 tail rotor blades are twoway interchangeable with the 369D21615
tail rotor blades in sets of two only (installed on the same inboard or outboard hub).
The 369D21642501, 503, 505, 507 tail rotor blades are twoway interchangeable with the 369D21606
tail rotor blades in sets of two only.
(39) The 369H1203BSC, 11, 21, 31, 51 and 61 lead lag link assemblies can only be installed using the
369H1235BSC bearing.
(40) The 369H120353 lead lag link assembly can only be installed using the 369H12351 bearing.
(41) The 369N260811 Control Support Bracket must be removed from 600N helicopters equipped with YSAS
(Ref. SB600N040).
(42) RIN = (29 x Hrs.) + (1 x TE).
(43) The tensiontorsion straps have a 5 year calendar life that starts the day the package is opened (Ref. Sect
642530). If the date the package was opened is unknown, the 5 year calendar life is based on the
manufacturing cure date.
For straps installed before 06 March 2008 on model 500N helicopters serial numbers LN001 thru LN105
and Model 600N helicopters serial numbers RN003 thru RN074, the initial calendar replacement is based
on the cure date on the strap. Refer to Table 2 to find the expiration date.
(44) 500N53115 straps previously installed on MD900 helicopters are life limited to 2,500 hours when installed
on 500N and 600N series helicopters.
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MAINTENANCE MANUAL
Table 2. TensionTorsion Strap Expiration Date

Manufacturers Cure Date Expiration Date
Before 03/1999 09/2008
03/1999 thru 02/2001 03/2009
03/2001 thru 02/2005 03/2010
03/2005 thru 02/2008 Cure Date Plus 5 Years
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Section
040001
Airworthiness
Limitations
Supplements
MAINTENANCE MANUAL
UK CAA ALS SUPPLEMENT

1. UK CAA Airworthiness Limitations
Section Supplement
NOTE:
D The following components are further
limited when helicopters are operating
under UK CAA TC.
D Refer to 040000 for all other Compo-
nent Mandatory Replacement Times and
Component Mandatory Inspections.
Airworthiness Limitations
Component Mandatory Replacement Schedule
Component Part Number Finite Life Mandatory
(1) (2) Hours (RIN) Inspection
(1) Hours
Main Rotor System
Drive shaft, main rotor 600N5510 14000 (1,000,000) (3)
Tailboom
Tailboom assembly 600N3500503 800 (4)
NOTES:
(1) Lifelimited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Lifelimited components removed at
retirement are to be destroyed or conspicuously marked to prevent inadvertent return to service. Parts are
applicable only on models under which a service life is listed.
(2) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(3) RIN = (50xHrs.) + (3xTE)
(4) The 600N3500503 tailboom may be reworked to a 600N3500505 tailboom by modifying the attachment
fittings to all steel fittings.
REVISION: DATE FAA SIGNATURE AND DATE *
Initial Issue: 24 May 2000
* FAA approval in behalf of UK CAA per letter, Winnert to Wang, Ref. 9/33/0649/A26479, Dated 2 May 2000.
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040001 Revision 26
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Revision 43 040001
MAINTENANCE MANUAL
Chapter
05
Continued
Airworthiness
MAINTENANCE MANUAL
TABLE OF CONTENTS
050000 Continued Airworthiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Checks/Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General Description of Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Continued Airworthiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Records of Aircraft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Additional Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Visual Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. General Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Overhaul/Recommended Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Component Overhaul or Recommended Replacement Schedule . . . . . . . . . . . . . . . . 1
Table 1. Component Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 2. Component Recommended Replacement Schedule . . . . . . . . . . . . . . . . . 3
100Hour or Annual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. 100Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. 100Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Retirement Index Numbers Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 2. Permanent Record of Retirement Index Numbers/Torque Events . . . . . 11
300Hour Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. 300Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. 300Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Yearly Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Special Inspection Hourly and Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Special Inspections Hourly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 2. Special Inspections Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Page i
MAINTENANCE MANUAL


Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Overtorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Sudden Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Conditional Inspection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1. Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Page ii
MAINTENANCE MANUAL
Section
050000
Continued
Airworthiness
MAINTENANCE MANUAL
CONTINUED AIRWORTHINESS
CHECKS/INSPECTIONS
1. General Description of Inspections (1). COMPONENT OVERHAUL/RE-
COMMENDED REPLACEMENT
The following Continued Airworthiness (Ref. Sec. 051000) is a schedule for
Sections specify inspections and other mainte- the overhaul and recommended replace-
nance required under the Federal Aviation ment of components and/or assemblies
Regulations unless an alternative program has and scheduled maintenance checks.
been FAA approved.
(2). 100HOUR OR ANNUAL INSPEC-
NOTE: Because this manual pertains to MDHI TION CHECKLIST (Ref. Sec.
model 369D, 369E, 369FF, 500N and 600N 052000) is a schedule of inspections
helicopters (including the basic 500MD con- that must be accomplished every 100
figuration), it may contain inspection re- hours of helicopter operation or on a
quirements applicable to specific equipment 12month (annual) basis.
not installed on individual helicopters. An Annual Inspection is required on
When this situation is encountered, require- this helicopter for continued airworthi-
ments that are not applicable should be dis- ness and may be accomplished in
regarded. combination with a 100hour inspec-
tion.
The inspection intervals designated herein are
the maximum allowable and should not be NOTE:
exceeded. When unusual local conditions, such
D To comply with the requirements of ser-
as environmental conditions, utilization, etc.
vice bulletins which have been incorpo-
dictate, it is the prerogative and responsibility
rated into the appropriate maintenance
of the operator to increase the scope and
and inspection manuals, the latest
frequency of the inspections as necessary to
100Hour or Annual Inspection must be
ensure safe operation. Each item shall conform
used.
with the FAA Requirements, A.D.s and
Manufacturer Bulletins and Letters. Over D Refer to applicable RollsRoyce Engine
flying the inspection interval, or any change Operation and Maintenance Manual (Ref.
desired to the requirements of this chapter, Table 201, 010000) for detailed require-
may be requested through the local aviation ments on inspection of the engine.
regulatory authority.
(3). 300HOUR INSPECTION CHECK-
A. Airworthiness Limitations LIST (Ref. Sec. 052010) is a schedule
of inspections that must be accom-
Refer to section 040000 for mandatory plished every 300 hours of helicopter
inspections and component mandatory operation.
retirement schedule.
(4). YEARLY INSPECTION CHECK-
B. Continued Airworthiness LIST (Ref. Sec. 052015) is a schedule
of inspections that must be accom-
This section contains the requirements for plished on a yearly basis.
Component Overhaul/Recommended Replace-
ment, 100Hour or Annual Inspection Check- (5). SPECIAL INSPECTIONS (Ref. Sec.
list, 300Hour Inspection Checklist, Special 052020) consist of inspections that
Inspection Schedule and Conditional Inspec- are contingent upon elapsed flight time
tions. or calendar time.
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050000 Revision 38
MAINTENANCE MANUAL
(a). Special Inspections Hourly should include a visual examination of the area,
be referred to for additional inspec- component, detail, assembly, or installation
tion requirements that must be and its surrounding environment, as well as
performed at specified periodic any associated equipment within the immedi-
hourly intervals. ate vicinity, using any inspection aids consid-
ered necessary.
(b). Special Inspections Calendar
should be referred to for additional A. General Visual Inspection
inspection requirements that must be
A visual inspection that will detect obvious
performed at specified periodic
unsatisfactory conditions/discrepancies. This
calendar intervals.
type of inspection may require cleaning,
(6). CONDITIONAL INSPECTIONS (Ref. removal of fillets, fairings, access panels/doors,
Sec. 055000) includes inspection etc.
requirements for unusual or other (1). Metal parts (all metal parts, bodies, or
specific conditions or circumstances casings of units in systems and in
that might occur. electrical, instrument, and radio
installations, ducting, tubing, rods, and
2. Documentation
bellcranks). Inspect for the following:
A. Records of Aircraft Inspection (a). Cleanliness, external signs of dam-
(1). Aviation regulatory agencies require age, leaks, overheating, discharge, or
pilots, mechanics, owners and opera- fluid contamination.
tors to be familiar with, and to main- (b). Obstruction of drainage or vent holes.
tain records of aircraft maintenance,
inspections and repairs. This includes, (c). Correct seating and sealing of
but is not limited to, Airworthiness fairings and serviceability of fasten-
Directives, Manufacturers Notices, ers.
Scheduled Inspections and Time/Cycle
(d). Security of attachment, fasteners,
limitedlife components.
and connections.
B. Additional Documentation (e). Distortion, dents, scores, chafing,
(1). Additional documentation is required to pulled or missing fasteners, rivets,
be available, or inside the aircraft, bolts, or screws.
during operation. This documentation (f). Signs of cracks or wear.
includes: Airworthiness and Registra-
tion Certificates, Rotorcraft Flight (g). Separation of bond.
Manual, Weight and Balance informa-
(h). Failure of welds or spot welds.
tion and Radio Permits. It is important
that all required documentation be (i). Deterioration of protective treatment
reviewed and revised as necessary and corrosion.
during regular inspections, mainte-
nance and operation of the helicopter. (2). Composite, rubber, fabric, fiberglass,
and plastic parts (coverings, ducting,
3. Visual Inspection Criteria flexible hoses, flexible mountings, seals,
insulation of electrical cables, windows,
Any time an area of the helicopter is visible etc.). Inspect for the following:
during an inspection or maintenance action,
the following "Visual Inspection Criteria" shall (a). Cleanliness, cracks, cuts, chafing,
be accomplished without requiring disassem- kinking, twisting, crushing, or
bly or removal of adjacent equipment unless contraction (sufficient free length).
otherwise specified. It will normally apply to (b). Damage, delamination, or deteriora-
those areas, surfaces, or items which become tion.
visible by the removal or opening of access
doors, panels, fairings, or cowlings. It shall (c). Crazing.
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Revision 38 050000
MAINTENANCE MANUAL
(d). Loss of flexibility (other than fabric (b). If protective covers are required to be
covered component). removed, check for cleanliness,
scoring, pitting or burning of con-
(e). Overheating. tacts, brushes for condition, and
security of exposed contacts.
(f). Fluid saturation.
(c). Overheating.
(3). Control System Components. Inspect (d). Fluid contamination.
for the following:
NOTE: For detailed Wiring Inspection criteria,
(a). Correct alignment, no binding. refer to CSPHMI3, Section 960000.
(5). Wire harness. Inspect for the following:
(b). Distortion, signs of bowing, scoring,
chafing, fraying, kinking, signs of (a). Routing, contact with structure,
wear, flattening, cracks, or loose proper support and protection.
fasteners.
(b). Strain at termination points, free
movement of shockmounted or
(c). Deterioration of protective treatment hinged equipment and proper slack
or corrosion. for equipment installation and
maintenance.
(d). Electrical bonding correctly posi-
tioned, undamaged, and secure. (6). Inside fuel cell areas. Inspect for the
following:
(e). Attachments, end connections, and
(a). Leaks, cleanliness, foreign objects,
locking devices secure.
cracks.
(4). Electrical components (circuit protec- (b). Components for security and general
tion devices, wiring, connectors, plugs, condition.
motors, generators, actuators, relays,
solenoids, and contacts). Inspect for the (c). Plumbing, and wiring for security,
following: and general condition.
(7). Markings, labels, and placards. Inspect
(a). Cleanliness, obvious damage, corro- for the following:
sion, security of attachments and
connections. (a). Legibility and security of attachment.
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050000 Revision 38
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Revision 38 050000
MAINTENANCE MANUAL
Section
051000
Continued
Airworthiness
MAINTENANCE MANUAL
COMPONENT OVERHAUL/RECOMMENDED REPLACEMENT
1. Component Overhaul or Recommended Neither the assignment of an airworthiness
Replacement Schedule life to a component nor failure to assign an
airworthiness life constitutes a warranty of
Table 1 is the Overhaul Schedule. The listed any kind. The only warranty applicable to the
components or assemblies should be removed helicopter and any components is that
from the helicopter and overhauled at inter- warranty included in the Purchase Agreement
vals specified. for the helicopter or the component.
Table 2 is the Recommended Replacement
Schedule. The listed components should be NOTE: Hours for the 369F Model helicopters
removed from the helicopter and scrapped at will be the same as the 369FF unless other-
intervals specified. wise noted.
Table 1. Component Overhaul Schedule

Component (1) Model Part Number (2) Hours
Main rotor transmission assembly 369D/E/FF 500N 369D25100 3000
369D25100 4000 (12)
369D/E/FF 500N 369F5100 5000
600N 369F5100 3000
Main rotor swashplate assembly 369D/E/FF 500N 369D27609 2770 (3)(9)
600N 600N76303 2700 (4)(9)
Main rotor hub assembly 369D/E/FF 500N 369D21200 2770 (7)(9)
600N 600N1200 2700 (7)(9)
Landing gear damper 369D/E/FF 500N 369D26300 On Cond. (6)
369D26301 On Cond. (6)
600N 600N6300 On Cond. (6)
Overrunning clutch assembly 369D/E/FF 500N 369A5350603 1800 (5)
369A5350605 1800 (5)
369D/E/FF 500/600N 369F5450 1800 (10)(11)
Tail rotor transmission 369D/E 369D25400 4800
369FF 3365
369D/E 369D25300 4800
Starter/Generator (8) 369D/E 500N 369A4550 1200
369FF 600N 369D28550 1200
NOTES:
(1) Components interchanged between models or configurations must be restricted to the lowest service life
indicated for the models or configurations affected. Components removed at retirement are to be destroyed
or conspicuously marked to prevent inadvertent return to service. Parts are applicable only on models
under which a service life is listed.
(2) Service life shown for basic part number applied to all dashnumbered versions unless otherwise
indicated.
(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref.
CSPCOM5, Sec. 623010).
(4) Bearing assembly must be relubricated every 2 years or 2700 hours, whichever occurs first (Ref.
CSPCOM5, Sec. 623060).
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051000 Revision 34
MAINTENANCE MANUAL
(5) Under some operating conditions, overrunning clutch splines may need to be regreased more often than at
the 100hour intervals and bearings may need to be regreased more often than at the 300hour intervals.
With no cargo hook attached, inspect and regrease splines every 100 hours and bearing every 300 hours
(Ref. Sec. 631000, Installation of Overrunning Clutch Subassembly and CSPCOM5, Ball Bearing
Inspection and Grease Repack).
With cargo hook attached, inspect sprag assembly, inner race and outer race every 300 hours or 300 hours
of actual hook time when logged separately as per FAR 91.417, regrease clutch splines every 100 hours
and bearing every 300 hours (Ref. Sec. 631000, Installation of Overrunning Clutch Subassembly and
CSPCOM5, Ball Bearing Inspection and Grease Repack).
(6) When inspected per Landing Gear Damper Inspection (Ref. Sec. 321000 for 369D/E/FF 500N, or Sec.
321060 for 600N).
(7) Use only main rotor hubs overhauled by MDHI or approved MDHI Licensees.
(8) Refer to data plate to determine start/generator manufacturer.
(9) The shelf life of bearings preserved with grease is limited to 4 years.
(10) Regrease overrunning clutch bearings every 300 hours (Ref. CSPCOM5, Sec. 631015).
(11) Interim hours: life extension testing in progress.
(12) The 369D25100 main rotor transmission overhaul time may be extended from a mandatory 3000 hour
overhaul time to a mandatory 4000 hour overhaul time, provided, the transmission is operated with Mobil
SHC626 since last overhaul.
The transmission shall not exceed 3000 hours if cargo hook time has reached a quantity of 750 hours.
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Revision 40 051000
MAINTENANCE MANUAL
Table 2. Component Recommended Replacement Schedule

Component (1) Model Part Number (2) Hours
Tail rotor swashplate (duplex) bearings 369D/E/FF 369D21832 On Cond. (3)(9)
Fan support bearing 500/600N 500N5364 2400 (8)(9)
Pitch plate bearing 500/600N 500N7120 2400 (8)(9)
Thrust bearing cup, upper 369D/E/FF 500N 369D21255 On Cond. (3)(9)
Thrust bearing cone, upper 369D/E/FF 500N 369D21254 On Cond. (3)(9)
Thrust bearing cup, upper 600N 369D21255 600 (5)(9)
Thrust bearing cone, upper 600N 369D21254 600 (5)(9)
Thrust bearing cup, lower 369D/E/FF 500N 369D21257 On Cond. (3)(9)
Thrust bearing cone, lower 369D/E/FF 500N 369D21256 On Cond. (3)(9)
Thrust bearing cup, lower 600N 369D21257 5400 (4)(9)
Thrust bearing cone, lower 600N 369D21256 5400 (4)(9)
Bearings, oil cooler blower 369D/E/FF 500/600N 369H56553 1200
369D/E/FF 500/600N 369H56555 1200
Belt, oil cooler blower 369D/E/FF 500N 369D25623 1200
600N 93920219 1200
Cyclic stick trim switch (7) 369D/E/FF 500N A21810064602 1000
NOTES:
(1) Limitedlife or scheduled replacement components interchanged between models or configurations must
be restricted to the lowest service life indicated for the models or configurations affected. Limitedlife or
scheduled replacement components removed at retirement are to be destroyed or conspicuously marked
to prevent inadvertent return to service. Parts are applicable only on models under which a service life is
listed.
(2) Service life shown for basic part number applied to all dashnumbered versions unless otherwise
indicated.
(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref. Sec.
643000, Tail Rotor Swashplate Bearing Regreasing).
622060, Main Rotor Hub Tapered Bearing Grease Repack, Inspection and Replacement).
622060, Main Rotor Hub Upper Bearing Grease Repack, Inspection and Replacement).
(6) Deleted
(7) Installed in 369D27133 grip assembly made by Guardian Electric Co., PN A21896671400 (Ref. Sec.
671020, Cyclic Stick Grip Switch Replacement (Standard Grip)).
642530, AntiTorque Fan Bearing Regreasing).
(9) The shelf life of bearings preserved with grease is limited to 4 years.
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051000 Revision 37
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Revision 34 051000
MAINTENANCE MANUAL
Section
052000
Continued
Airworthiness
MAINTENANCE MANUAL
100HOUR OR ANNUAL INSPECTION CHECKLIST
1. 100Hour or Annual Inspection NOTE:
D The Chap/Sect column of the following
table is for reference unless a specific in-
This check sheet is designed to be used when spection requirement is called out. If
performing 100Hour or Annual inspections as there is only two numbers in the column,
defined under FAR, Part 43, Appendix D. This it refers to the Chapter. If there is three
checklist, when completed, should be kept as a numbers, it refers to the Section the in-
permanent part of the helicopters records. spection is found.
Adherence to Maintenance Manual informa- D Refer to applicable RollsRoyce engine in-
tion is required, and the manual should be spection check list for required engine
consulted when using the checklist. maintenance.
Table 1. 100Hour or Annual Inspection
Registration No. Serial No.
Helicopter Hours Torque Events
Model Requirement Chap/Sect Initial
GENERAL
ALL Thoroughly clean helicopter and engine prior to start of inspection. 20
ALL Remove trim panels, covers and access panels as necessary. 525000
ALL Ensure all placards and markings are installed. 110000
ALL Ensure compliance with component mandatory retirement schedule. 040000
ALL Calculate and record TEs or RINs, of all affected components, in Table 2. 040000
ALL Ensure compliance with component overhaul schedule. 051000
ALL Ensure compliance with all applicable airworthiness directives, service N/A
bulletins and special inspections.
ALL Review aircraft maintenance records for recorded discrepancies and correct N/A
discrepancies as applicable.
ALL Refer to related manufacturers publications for detailed requirements on 010000
inspection of engine, starter/generator, battery and all installed STC
equipment.
EXTERIOR
ALL * Air intake for cleanliness and foreign matter. 71
* Visible portion of engine compressor inlet for foreign object damage.
CAUTION: Ensure that compressor cover is installed to prevent FOD.
ALL Engine air plenum chamber for: 71
* Damage and cleanliness. 53
* Wear and security of internal components.
* Particle separator mounting structure for cracks or damage.
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MAINTENANCE MANUAL
Table 1. 100Hour or Annual Inspection (Cont.)

ALL Fuselage upper surfaces for: 52
* Damage and condition. 53
* Mast base drain holes clean and free of debris (blow air thru holes to
ensure no clogging).
* Engine air inlet fairing free from damage. No delamination noted. Bypass
door operationally checked. Seals free from damage.
* Engine air bypass door operationally checked. Seals free from damage. 71
Cable system checked for smooth operation.
* Engine access doors for proper operation of latches and closure,
distortion, damage, cracks and security. 52
ALL Fuselage for: 52
* Damage and condition. 53
* Compartment fresh air vents in doors and front of canopy for easy of
operation and security.
* Fuel cell vent fairings free of obstructions and obvious damage.
* Pilots and passenger/cargo compartment doors for condition of door
glass, vents and proper operation of latching and locking mechanisms.
* Door hinges and pins for play or wear. Ensure door pin locking tab is
engaged with slot in frame.
* No evidence of oil leakage around fuselage drain holes.
369D/E/FF Sta. 142.0 tail rotor control bellcrank support for cracking or damage, use 672010
bright light and mirror (Ref. Upper Fuselage and Tailboom Control Linkage
Inspection).
500/600N Antitorque fan inlet for: 53
* Screen for cleanliness and damage.
* Attaching hardware for security.
* Interior of fan inlet for cleanliness and damage.
* Driveshaft cover for damage.
ALL * Check for no gap between tailboom and fuselage at attach points. 53
* Check tailboom skin around stabilizer fittings for cracks.
* Tailboom attachmenttofuselage for security, evidence of corrosion or
cracks, loose rivets or buckling.
Page 2
Revision 39 052000 Form HOE005 (Rev 5/04)
MAINTENANCE MANUAL

500/600N * Thruster cones and tip cap (500N only) for damage and security. Inspect 534030
for wear between thruster cones and tailboom at points of contact. 535030
* Using a flashlight and 10X magnifying glass, inspect horizontal stabilizer
mounting brackets for cracks (pay particular attention to the forward inboard
legs) (Ref. Tailboom Inspection).
* Using a bright flashlight, inspect fore and aft radii of the lower portion of
the three upper slot bridges for cracks, illuminate area under the flap. The
flap may be raised slightly, using finger pressure only, to aid in checking this
area (Ref. Tailboom Inspection).
* Using a bright light and 10X magnifying glass, inspect the four tailboom
attachment lugs for cracks and fiber damage. Pay particular attention to area
on top of the lug from the radius block to 2 inches aft (Ref. Tailboom
Inspection).
* Tailboom closeout fairings for security of attachment hardware. Inspect
for damage and chafing between closeout fairing and tailboom.
369D/E/FF Horizontal stabilizer for: 535010
* Skin damage and loose rivets.
* Tip plates for damage. Check for secure attachments (Ref. Horizontal
Stabilizer and Tip Plates Inspection).
500/600N Horizontal stabilizer for: 53
* Skin damage and loose rivets.
* Mounting fittings for cracks and security.
* Stabilizer attach bolts for security.
369D/E/FF Vertical stabilizer for: 535010
* Damage to leading and trailing edges and damaged stressed side panels
(no repair of side panels permitted).
* Mounting fittings for cracks and security.
* Tail skid for obvious damage and security (Ref. Vertical Stabilizer
Inspection).
500/600N Vertical stabilizers for: 53
* Damage to leading or trailing edges and damaged side panels.
* Cracks in skin, no cracks permitted (pay particular attention to areas
around mounting bolts).
* Stabilizer attach bolts for security.
* Stabilizer mount bushings for wear, security and correct installation.
* Excess play in control linkage, bearings and security of attaching
hardware.
Page 3
MAINTENANCE MANUAL

LANDING GEAR
ALL Landing gear skid tubes and fairings for: 32
* Wear and damage in excess of permissible limits.
* Upper fairing fillets for freedom of movement and general condition.
* Strut attachment points for security and pivot (swivel) bearings for
excessive play.
* Landing gear dampers for correct extension, security of attachment and
for signs of fluid leakage. Pivot bearings for excessive play.
* Passenger steps for security and damage.
369D/E/FF Remove landing gear fairing fillets and visually inspect landing gear strut
500N assemblies for cracks and damage.
369D/E/FF For aircraft 369D; 001 & subs, 369E; 0001 thru 0528, 369FF; 0001 thru 0114
500N and 500N; 001 thru 077: Remove plug button from inboard of fairing
assembly. Using a bright light and 10X magnifying glass, inspect rivet hole in
underside of strut for cracks. If crack is found, strut must be scrapped.
CABIN
ALL Compartment heat and antiicing valve controls for: 21
* Easy and correct operation and rigging.
* Heating system heat diffusers for security.
ALL * Seat belts for condition and security. 25
* Inertia reels for condition and proper extension/retraction.
ALL Pilot/copilot controls for: 67
* Wear, looseness and general condition of control rods and rod end 76
bearings.
* Quickrelease pins for condition.
* Cyclic, collective and antitorque controls for free movement.
* Cyclic trim actuators for security.
* Collective torque tube, support bracket and bungee support bracket for
evidence of cracks, gouges or other visible damage in attach lug and bungee
support bracket attach areas; gaps between bracket and cradle cap of
collective torque tube (use bright light and mirror).
* N1 power controls for obvious damage.
* Check for minimum cyclic friction adjustment (resistance to turning spring
with fingers).
* Flight control system oneway lock (Uniloc) for oil leakage, condition and
security. Fluid reservoir 1/2 3/4 full; replenish if low.
Page 4
MAINTENANCE MANUAL

NOTE: With main rotor blades stationary, some friction drag is felt in the cyclic. The collective also has some drag,
plus resistance of the collective bungee spring. Heavy drag is an indication of droop stop deformation caused
by droop stop pounding.
ALL Engine N1 and N2 (N/A 600N) power controls for: 76
* Free movement, full travel, security, obvious damage and proper rigging.
* Pilots and copilots throttle rigging checks at FULL, GROUND IDLE and
CUTOFF positions.
MAIN ROTOR
ALL Main rotor mixer control pushpull rods, links, scissors and bellcranks for 62
excessive bearing play, bent rods or links, worn bushings and cracked 67
bellcranks or brackets; all rodends centered.
ALL Main rotor pitch control rod assemblies, upper and lower rod end bearing for 623000
evidence of axial play and for any extrusion, displacement or damage to the 623060
bearing teflon liner. Check that all rodends are centered and security of
lockwire (Ref. Pitch Control Rod Inspection).
ALL Swashplate for evidence of galling or corrosion of spherical bearing, and 62
seals for deterioration and evidence of grease leakage. Upper and lower dust
boots free from damage and security. Swashplate interrupters and magnetic
pickup secure.
ALL Main rotor hub retention strap assemblies for breaks or cracks in strap pack 622000
laminations. Check visible portions of both lead and lag legs of pack in each 622060
pitch housing (Ref. Main Rotor Strap Pack Lamination Inspection). Refer to
040000 for strap pack lamination airworthiness requirements.
ALL Outboard ends of main rotor hub retention strap assemblies for gaps 622000
between pack laminates (Ref. Main Rotor Strap Pack Lamination Inspection). 622060
ALL * Main rotor hub feathering bearings for excessive wear (Ref. Main Rotor 622000
Hub Inspection). 622060
* Main rotor droop stop ring for corrosion, dents and scratches.
* Main rotor droop stop striker plate rollers for play and excessive wear.
* Main rotor droop stop follower attachment pins for proper installation.
* Main rotor droop stop plunger for corrosion, dents and scratches.
ALL Main rotor blade damper assemblies for obvious damage, security and 622000
excessive play in blade and pitch housing bearings, bonding of elastomeric 622060
material and corrosion (Ref. Main Rotor Damper and Attachments
Inspection).
ALL Using bright light and 5X magnifying glass, inspect all main rotor hub 622000
assembly leadlag links for corrosion, discoloration, pitting, intergranular 622060
cracks or stress corrosion cracks. Any discoloration or pitting is evidence of
more than superficial corrosion, and the main rotor hub must be removed for
replacement of leadlag links (Ref. Main Rotor Hub Inspection).
Page 5
MAINTENANCE MANUAL

ALL Main rotor hub bearings for roughness by rotating main rotor assembly 622000
several times by hand and listening for unusual noise (Ref. Main Rotor Hub 622060
Inspection).
NOTE: Do not confuse with normal noload transmission and overrunning clutch noise.
ALL Main rotor blade and damper attach pins tight and levers properly locked. 62
ALL Entire trailing edge and tabs for nicks, scratches and cracks generating from 621000
trailing edge (Ref. Main Rotor Blade Inspection).
WARNING: Using a bright light and 5X to 10X magnifying glass, inspect root fitting,
attach lugs and doublers for cracks and security.
ALL Inspect main rotor blade root fittings, attach lug and leadlag link attach lug 621000
every 100 hours in accordance with Main Rotor Blade Upper and Lower Root
Fitting, Attach Lug and LeadLag Link Attach Lug Inspection (100 Hour). Pay
particular attention to the lower side of the root fitting.
ALL Using a bright light and 10X magnifying glass, inspect main rotor blade 621000
abrasion strips for security of bonding on lower and upper surfaces, and by
tapping at bond lines. Any blisters, bubbling or lifting of abrasion strip
indicates a void (Ref. Main Rotor Blade Inspection).
ALL Tip area of main rotor blades for evidence of corrosion; pay particular 621000
attention to mating area of blade skintotip weight interface; verify integrity
of sealant coating (Ref. Main Rotor Blade Forward Tip Cap Inspection and
Corrosion Protection).
ALL Drain holes in main rotor blade aft tip cap and vent holes in lower skin for 62
clogging. Main rotor tip caps for security and evidence of corrosion.
369D/E/FF Main rotor hub fairing for cracks, damage and security. 62
500N
DRIVE TRAIN
ALL Main transmission lubrication and cooling system for: 63
* Main transmission case and cooling installation for evidence of leakage
and security of attachment.
* Oil cooler blower, mount, ducting and hardware for security and damage.
* Oil lines for chafing damage.
* Clamps attached to oil lines for evidence of cushion wear or deterioration
(if noted, remove clamp and inspect tube under clamp for chafing damage).
* Pressure switch for security and deterioration; wiring for chafing.
369D/E/FF Tach generator for security and deterioration; wiring for chafing. 63
500N
ALL Rotor brake for: 63
* Pucks and disc for wear and general condition.
* Hydraulic lines for security and leaks.
* Master cylinder for leaks.
* Air in system (spongy feel at brake actuating handle when force is
applied).
Page 6
MAINTENANCE MANUAL

ALL Overrunning clutch for: 63
* Evidence of oil leakage.
* Proper operation: turn rotor in forward direction by hand engine must
decouple; turn rotor in reverse direction engine must rotate (listen for
turbine noise during reverse rotation). Rotor brake disc should not drag.
NOTE: Normal seal drag may be sufficient to rotate engine at low rpm.
369D/E/FF For aircraft equipped with 369A5350 overrunning clutch, regrease clutch 63
500N splines.
ALL Enginetomain transmission drive shaft couplings and shaft for condition and 631000
security of attachment.
Bendix couplings only: inspect shaft coupling diaphragms for scratches, nicks
or cracks (Ref. Main Transmission Drive Shaft Inspection (Bendix)).
500/600N * Main transmissiontofan transmission drive shaft for dents, bulkhead 63
chafing and obvious damage.
* InterConnect drive shaft for dents and obvious damage.
* Free movement of control rod thru interconnect drive shaft.
369D/E Bendix couplings only: Check tail rotor blade tip movement in excess of 0.75 63
inch, without main rotor blade movement, when tail rotor blades are rocked
back and forth in plane of rotation.
369D/E/FF Tail rotor drive shaft for: 631510
* Evidence of buckling, dents, bulkhead chafing and obvious damage.
* Align aft coupling index stripe with corresponding tail rotor transmission
stripe and verify that bulkheadtodrive shaft index stripes align (Ref. Tail
Rotor Drive Shaft Twist Inspection).
ANTITORQUE
Tail Rotor System
369D/E/FF Tail rotor transmission for: 632510
* Corrosion, excessive oil leakage, cracks and other damage.
* Check torque of mounting nuts (also tailboom extension hardware on
369FF helicopters) (Ref. Tail Rotor Transmission Installation).
369D/E/FF Tail rotor and pitch control assembly for: 64
* Binding and unusual sounds (teeter blades to check for binding).
* Control rod, pitch control links, hub and drive fork for play or damage.
* Boots for installation and deterioration.
* Retaining nut and lockwasher secure (no broken tangs noted and nut
has not rotated, visual inspection of torque stripe).
* Pitch control for evidence of seal rotation or loss of grease.
Page 7
MAINTENANCE MANUAL

369D/E/FF Drive fork for; 64
* Elastomeric bearing elements for bond failure.
* Apply teetering force by hand (stoptostop) to rotor blades and inspect
elastomers for radialmolded ridges on each bearing face. Discontinuity in
molded ridges indicates bearing failure. There should by no apparent motion
between the cage and fork, observed motion indicates bond failure.
NOTE: Light swelling, pock marks and crumbs are surface conditions and do not indicate bearing failure.
369D/E If equipped with conicaltype teetering bearings, torque check teeter bolt. 64
* Conical bearings for axial or radial play (no play allowed).
369D/E/FF Tail rotor blades for: 641000
* Evidence of damage, including leading edges, trailing edges, skin.
* Open vent and drain holes.
* Loose or damaged tip caps.
* Rivets securing tip cap for installation and condition.
* Abrasion strips free of damage, no excessive erosion noted and no
separation in bond around edges or at tip end of blade (Ref. Tail Rotor Blade
Inspection).
* While holding hub stationary, check tail rotor blade pitch bearings for
leadlag play in excess of 0.250 inch (6.35 mm) at blade tip. If excess play is
found, remove blades, replace pitch bearings and inspect hubtopitch
bearing contact surface of hub (Ref. COM).
369D/E/FF Perform Tail Rotor Balance. 18
NOTARR AntiTorque System
500/600N * Rotate rotor system and check for unusual noises. 64
* Fan assembly for cleanliness and damage.
* Fan blades for excessive play.
* Fan seal for cleanliness, cracks, damage and corrosion.
* Check gap between fan blades and tip seal.
* Check gap between fan blades and hub.
NOTE: If any of these gaps for any blade exceeds the average gap of the other blades by more than 0.10 inch
(2.54 mm), remove and inspect the tensiontorsion strap for that blade.
500/600N Perform Fan Blade Inspection (100Hour). 642530
500/600N Fan Transmission for corrosion, excessive oil leakage, cracks, damage and 63
security on mounting frame. Drain line for cracks and security.
Page 8
MAINTENANCE MANUAL

500/600N Remove rotating cone and tip cap (500N) and inspect: 67
* Cables, cable ends and pulleys for condition and security. Perform
Forward and Center Cable Assembly Inspection and Sector Assembly and
Control Cable Inspection.
* Aft cable ends and turnbuckles for condition and security. Evidence of
corrosion pitting requires replacement.
* Rotating cone control tubes and cables for freedom of movement and
unusual sounds.
Reinstall rotating cone and tip cap (500N).
ELECTRICAL
NOTE: When possible, use auxiliary power source, not battery, during POWER ON inspection.
ALL XMSN OIL TEMP, FUEL FILTER and CHIPS warning lights; electrical circuits 950000
for continuity to lamps by connecting jumper wire from each sender or chip
detector terminal stud to an unpainted grounding surface; check each light
for illumination (Ref. Caution/Warning System Operational Check).
ALL Push PRESS TO TEST switch: all caution and warning lights ON; depress 95
instrument light rheostat knob; verify CAUTION lights dim.
369D/E/FF Conduct operational check of automatic reignition system; igniter noise heard PFM
500N and reignition indicator light functions. Reset as required.
CAUTION: Do not leave landing light ON for more that one minute during next check; lamp will overheat and
lamp life will be shortened.
ALL Exterior lighting (landing, position and anticollision lights) for proper 96
operation; all switches OFF after check.
WARNING: Do not leave pitot heater ON for more than one minute during next check; severe burns to
personnel may result.
ALL PITOT HTR switch ON for a few seconds. Heated pitot tube will feel warm to 95
the touch; turn switch to OFF after check.
600N Apply power to aircraft and disconnect CIT sensor (Ref. CIT (Compressor 760000
Inlet Temperature) Sensor Replacement); Verify ECU FAIL light illuminates.
Reconnect CIT sensor.
ALL Clean battery and inspect for: 96
* Connector pins for evidence of corrosion.
* Leakage (if battery is leaking (wet), remove and replace battery).
* Battery case for cracks in support flanges.
* Dc wiring for chafing caused by wiring rubbing against battery case.
* Deep cycle charge (recondition) battery every 100 hours or on
conditional basis at operators discretion.
ALL Functionally check and inspect all installed avionics, auxiliary or optional 97
systems and equipment. Do not actuate hoist guillotine or emergency floats.
Page 9
MAINTENANCE MANUAL

ENGINE COMPARTMENT
ALL Exhaust stack(s) and exhaust supports for cracks, defects and improper 78
attachment.
ALL Engine compartment plumbing and electrical relay installation on left or right 96
side oleo (landing gear damper) support fitting for good condition and
security of mounting. Diodes for broken terminals and wires. Diode bracket
for security and corrosion.
ALL Entire engine for: 71
* Loose bolts; loose or broken connections. 75
76
* Accessories for security and broken or missing lockwire.
* Fuel and oil lines for chafing and kinking.
* Fuel drain line valve for leakage.
* Oil cooler and cooler deflector for security and obvious damage.
* Accessible areas for obvious damage; evidence of fuel and oil leaks.
* Engine mounts for cracks and play in mounting hardware at engine and
airframe (retorque any loose mounting bolts).
* Fuel control and compressor exterior for condition and security.
369D/E/FF RPM governor lever control rod (replace if aluminum). 761000
500N
369D/E/FF Clean and lubricate drive splines of startergenerator drive shaft, and female 96
500N splines in engine accessory gear case on dry spline installations.
369D/E/FF Antiice air tubes and compressor scroll for cracks or breaks at the antiice 751000
500N air valve and bleed port. If cracks exist, check engine for possible vibration
causes (Ref. Engine Antiicing System and applicable Allison Engine
Operation and Maintenance Manual).
AFTER INSPECTION
ALL Touchup all damaged paint and exterior markings, as necessary. 20
ALL Ensure all fluid levels are correct; service as required. 12
ALL Perform operational check of particle separator filter (Ref. Scavenge Air 711010
Operational Check).
Page 10
MAINTENANCE MANUAL

ALL Install or close all stressed panels, covers and trim panels removed or 525000
opened for inspection. Check closure, fit and security. All loose equipment for
proper stowage.
CAUTION: Helicopter must not be flown unless controls access panel and fuel cell access panels in cargo
compartment are securely installed. These are stressed panels.
POST INSPECTION RUN UP
See applicable Pilots Flight Manual for cockpit check and engine starting procedures. For troubleshooting
procedures, refer to applicable section of this manual.
100HOUR OR ANNUAL INSPECTION CERTIFICATION
It is certified that this helicopter has been thoroughly inspected as required by FAR, found to be airworthy, and
appropriate entries made in the helicopter log book. It is further certified that the helicopter conforms to FAA
specifications, that all FAA Airworthiness Directives and Manufacturers Service Notices and Maintenance
Manual data have been complied with, and the helicopter records are in proper order
Signature
Rating Type or Certificate No.
Date
2. Retirement Index Numbers Attachment Refer to Section 040000 for components
requiring calculation of RINs/TEs and
Table 2 is to be used for calculating and information pertaining to calculation of
recording the Retirement Index Number (RIN) RINs/TEs.
or Torque Events (TE) of components that are
affected by Torque Events (TE).
Component must be scrapped when it reaches
This record of RINs/TEs should be kept as a 1,000,000 RINs or maximum TEs (Ref. Sec.
permanent record. 040000).
Table 2. Permanent Record of Retirement Index Numbers/Torque Events
Component Part No. Serial No. Hours TEs RINs Signature
Page 11
MAINTENANCE MANUAL
Table 2. Permanent Record of Retirement Index Numbers/Torque Events

Component Part No. Serial No. Hours TEs RINs Signature
Page 12
MAINTENANCE MANUAL
Section
052010
Continued
Airworthiness
MAINTENANCE MANUAL
300HOUR INSPECTION CHECKLIST
1. 300Hour Inspection NOTE:
performing scheduled inspections as defined there is only two numbers in the column,
under FAR Part 91. This checklist, when it refers to the Chapter. If there is three
completed, should be kept as a permanent part numbers, it refers to the Section the in-
of the helicopters records. Adherence to spection is found.
Maintenance Manual information is required, D Refer to applicable RollsRoyce engine in-
and the manual should be consulted when spection check list for required engine
using the checklist. maintenance.
Table 1. 300Hour Inspection
Registration No. Serial No. Helicopter Hours
EXTERIOR
ALL Retorque tailboom attachment bolts. 53
500/600N Remove rotating cone and tip cap (500N) and inspect: 53
* Cone rollers for condition and security.
* Four fasteners that attach 500N37601 upper input shaft to the
stationary thruster for play (replace pins and collars if any play is found).
* Three fasteners that attach 500N3759 support shaft assembly for play (if
play is found in top bolt, retorque to 10 15 inchpounds (1.13 1.69 Nm).
Replace pins and collars if any play is found in bottom fasteners).
Reinstall rotating cone and tip cap (500N).
369D/E/FF Remove engine inlet bypass door and inspect: 711010
* .Latches, hinges and hardware for condition, wear and security.
* .Cables, cable ends and pulleys for condition, corrosion and wear.
* Remove and replace the latch retention cotter pin (located inside the
attach U clamp) (Ref. Engine Air Inlet Bypass Door 300Hour Inspection).
369D/E/FF Check horizontal and vertical stabilizer attach bolts for proper torque (Ref. 535010
Horizontal Stabilizer Tip Plate Installation and Vertical Stabilizer Installation).
369D/E/FF Check lower surface of horizontal stabilizer for drain holes. Also check for 535010
gaps between upper and lower doublers and stabilizer skin (Ref. Horizontal
Stabilizer and Tip Plates Inspection).
500/600N Control tubes and bellcranks in horizontal stabilizer for condition and security. 53
Page 1
Form HOE006 (04/06) 052010 Revision 39
MAINTENANCE MANUAL
Table 1. 300Hour Inspection (Cont.)

500/600N Inspect S.A.S. system for: 67
* Actuator for security and damage (no damage allowed).
* Wiring for condition and security (no wire chaffing, fraying or insulation
cracking allowed).
* Actuator mounting bracket for cracks, pay particular attention to area
around four rivet attach holes (no cracks allowed).
* Rate gyro and control box for security in mount and electrical connector
secure. Inspect mount for security and condition (no corrosion or cracks
allowed).
LANDING GEAR
ALL Perform Landing Gear Inspection. 321000
ALL Perform Cabin Entry Step Inspection. 321000
CABIN
ALL Remove instrument console base covers and inspect antitorque pedal 67
crossover torque tube and bellcrank for cracks, damage and security.
ALL Pushpull rods for excessive bearing play, wear and security. 67
ALL Perform TunnelRouted Control Rod Inspection. 671000
ALL Check oil tank for security and evidence of leakage and damage. 79
MAIN ROTOR
ALL Perform Swashplate Inspection. 62
ALL Perform LeadLag Bolt Inspection. 62
ALL Perform Main Rotor Hub Droop Angle Check. 62
ALL Perform Main Rotor Blade Inspection. 62
ALL Inspect main rotor mast, mast base and mast base support structure for 633000
evidence of cracks. Check with bright light and 5X magnifying glass. Visually
check mast support bolts for security and condition. Inspect internal bore for
chipping, orange peeling or flaking paint (Ref. Main Rotor Static Mast
Inspection and Repair).
ALL Inspect hoisting eyebolts for cracks or corrosion. 63
369D/E/FF 369D25510 drive shaft only, perform Main Rotor Drive Shaft Inspection 631000
500N (300Hour).
DRIVE TRAIN
ALL Remove, inspect and clean main transmission chip detectors. 63
369D/E/FF 369A5350 Overrunning Clutch: Perform Ball Bearing Inspection and Grease COM
500N Repack (300 Hour).
ALL 369F5450 Overrunning Clutch: Perform Ball Bearing Grease Repack (300 COM
Hour).
369D/E/FF Remove tail rotor drive shaft and check boom fairing and tailboom for 53
buckles, dents, bulkhead chafing and obvious damage.
Page 2
Revision 39 052010 Form HOE006 (04/06)
MAINTENANCE MANUAL

369D/E/FF Remove tailboom control rod and inspect for wear though hard anodized 672010
surface (Ref. Tailboom Control Rod Replacement); inspect grommets for
wear and deterioration.
369D/E/FF Check shaft damper for proper friction drag. Inspect damper for damage and 631510
security (Ref. Tail Rotor Drive Shaft Damper Inspection).
369D/E Check forward and aft coupling bolt and socket for indication of contact, 631510
Bendix couplings only (Ref. Tail Rotor Drive Shaft Inspection).
ANTITORQUE
Tail Rotor System
369D/E/FF Remove, inspect and clean chip detectors. 63
369D/E/FF Check for contact between tail rotor bellcrank and tail rotor transmission 67
housing at extreme right pedal travel.
369D/E/FF Tail rotor assembly: Elastomeric teeter bearings for wear; bond between 642000
concentric metal cones and elastomer rings of bearing assembly (Ref.
Elastomeric Bearing Inspection).
369D/E/FF Remove blade stop for thorough inspection; in particular, check for cracks or 643000
splits in stem area (Ref. Tail Rotor Blade Stop Inspection).
NOTARR AntiTorque System
500/600N Check balance weights for security. If any balance weight stud is found to be 64
loose, perform Fan Balance Stud Replacement.
500/600N Remove, inspect and clean fan transmission chip detector. 63
500/600N Remove tailboom: 53
Perform visual inspection of fan assembly for: 64
* Cracks, nicks or corrosion.
* Blades for cracks, nicks or impact damage.
* Check pitch horn counterweights for security. If counterweight(s) are
found loose, perform Pitch Horn Counterweight Set Screw Replacement
(Ref. Sec. 642530). NOTE: Access the forward counterweights through
the fan inlet (fan hub fairing must be removed).
* Gap between fan blade and tip seal and gap between fan blade and hub
(inboard end of the blade). If any of these gaps for any blade exceeds the
average gap of the other blades by more than 0.10 inch (2.54 mm)., remove
and inspect the tensiontorsion strap for that blade.
* Fan liner for cracks, debonding or corrosion of liner material.
* Pseal for tears, deterioration and debonding.
Reinstall tailboom (on 600N only, install new tailboom mounting bolts).
ELECTRICAL
NOTE: When possible, use auxiliary power source during POWER ON inspection, not battery.
ALL Perform Battery Temperature Sensing Switches Testing. 96
369D/E/FF Check TOT indicating system for proper calibration (Ref. TOT Indicating 953000
500N System Calibration).
Page 3
Form HOE006 (04/06) 052010 Revision 39
MAINTENANCE MANUAL

ENGINE COMPARTMENT
ALL Inspect starter/generator for: 96
* Condition of brushes, electrical connections and commutator.
* Screens for clogging.
* Condition of Oring on drive spline.
* Damper backplate and clutch for condition.
ALL Perform Fuel Filter (Bypass) Caution Light Pressure Switch Test. 280000
280060
NOTE: Also, perform this operational check whenever low pressure fuel pump filter element is replaced for any
reason, or if contaminated.
Page 4
Revision 38 052010 Form HOE006 (04/06)
MAINTENANCE MANUAL
Section
052015
Continued
Airworthiness
MAINTENANCE MANUAL

MAINTENANCE MANUAL
YEARLY INSPECTION CHECKLIST
1. Yearly Inspection NOTE:

performing special inspections as defined there is only two numbers in the column,
under FAR Part 91. This checklist, when it refers to the Chapter. If there is three
completed, should be kept as a permanent part numbers, it refers to the Section the in-
of the helicopters records. Adherence to spection is found.
Maintenance Manual information is required, D Refer to applicable Allison engine inspec-
and the manual should be consulted when tion check list for required engine mainte-
using the checklist. nance.
Table 1. Yearly Inspection

1 YEAR
EXTERIOR
ALL Perform Pitot Static System Inspection. 951000
ALL Check outside air temperature probe for security and obvious damage. 95
ALL Particle separator for condition and servicing. 71
NOTE: If equipped with a Donaldson Particle Separator, ensure Orings for rubber boot are 711010
not deteriorated (Ref. Donaldson Particle Separator Inspection).
ALL Perform engine air inlet Air Pressure Sensing Switch Calibration Check. 711010
711060
LANDING GEAR
369D/E/FF Perform Landing Gear Strut Inspection. 321000
500N
CABIN
ALL * First aid kit contents and security of attachment. 25
* Fire extinguisher for charge pressure and security of attachment. 26
ALL * Inspect seats, interior trim, panels and covers for damage and security. 25
* Inspect seat base structure for evidence of deformation.
ALL * Perform Tank Vent System Inspection. 280000
280060
369D/E/FF Inspect fuel vent system rollover valve for condition and operation (Ref. Tank 280000
500N Vent System Inspection).
NOTE: The 369H8108505, 369H8108M, 369H8108501M,503M and 369D281081 rollover valves do not re-
quire a yearly inspection.
Page 1
052015 Revision 29
MAINTENANCE MANUAL
Table 1. Yearly Inspection (Cont.)

ALL * Actuate and visually inspect fuel shutoff valve for proper operation. 280000
* Inspect fuel cell sending unit for electrical terminals and wiring for 280060
security and condition.
* Inspect wiring harness between sending unit and instrument cluster.
* Check FUEL LEVEL LOW caution light for proper operation (Ref. Fuel
Level Low Caution Light System Test).
600N Aircraft WITHOUT airframe fuel filter option: 280060
* Perform Fuel Transfer System Functional Check.
ALL Inspect instrument plumbing and electrical wiring for chafing, damage and 95
security. 96
NOTE: In the following inspection, do not pull on torque or oil pressure lines.
369D/E/FF Inspect torque and oil pressure lines from the firewall forward to the 95
500N instruments for seepage, chafing, cracking, damage and security.
ANTITORQUE
500/600N Drain fan transmission. Flush with sufficient new oil to remove sludge 12
accumulation. Refill with new oil.
369D/E/FF Drain tail rotor transmission. Flush with sufficient new oil to remove sludge 12
accumulation. Refill with new oil.
FLIGHT CONTROLS
500/600N Inspect forward thruster cable at Sta. 123.30 for crack in relieved area 67
between threads and swage.
Inspect the conduit cap of the telescopic swivel end for crack, corrosion and
obvious damage to the cable swage area or evidence of ball separation.
500N Inspect center thruster cable at Sta. 264.00 for crack in relieved area 67
600N Inspect center thruster cable at Sta. 292.00 for crack in relieved area 67
ELECTRICAL
NOTE: When possible, use auxiliary power source, not battery, during POWER ON inspection.
ALL Check wiring from battery connector to warning lights for continuity, use an 96
ohmmeter.
ENGINE COMPARTMENT
ALL Inspect firewall insulator panels for security and obvious damage. 53
ALL Inspect overrunning clutch firewall seal and engine compressor firewall 63
(plenum chamber) seal for proper sealing and good condition. 71
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Table 1. Yearly Inspection (Cont.)

4 YEARS
NOTE: Shelf life of bearings preserved with grease is limited to 4 years. For this reason, it is of extreme
importance that bearings carry the date of last lubrication or preservation and inspection. After 2 years of shelf
life, it is advisable to relubricate bearings upon installation.
ALL Clean, inspect and relubricate (repack) main rotor swashplate bearings that COM
have been in storage.
500/600N Clean, inspect and relubricate (repack) fan support and pitch plate bearings 64
that have been in storage.
369D/E/FF Clean, inspect and relubricate (repack) tail rotor swashplate (duplex) 64
bearings that have been in storage.
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Section
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Airworthiness
MAINTENANCE MANUAL

MAINTENANCE MANUAL
SPECIAL INSPECTIONS
1. Special Inspection Hourly and Calendar NOTE:

This table is a schedule of timephase inspec-
tions that are contingent upon elapsed flight
spection requirement is called out. If
time or calendar time. These inspections
there is only two numbers in the column,
require a Log Book entry. Adherence to
it refers to the Chapter. If there is three
Maintenance Manual information is required,
numbers, it refers to the Section the in-
and the manual should be consulted when
spection is found.
using this checklist.
D Refer to applicable RollsRoyce engine in-
spection check list for required engine
maintenance.
Table 1. Special Inspections Hourly

Model What to Inspect Chap/Sect
AFTER INSTALLATION OF NEW 369F5100 MAIN ROTOR TRANSMISSION
ALL Perform transmission runin (Ref. Main Transmission RunIn Procedure) 632025
2 10 HOURS AFTER INSTALLATION OF TAIL ROTOR TRANSMISSION
369D/E/FF Using drag torque previously recorded, apply a torque load of 75 95 inchpounds 632510
(8.47 10.73 Nm) plus the noted drag torque (noted for each individual nut) to each
mounting nut of the transmission (Ref. Tail Rotor Transmission Installation).
EVERY 10 HOURS or BEFORE FIRST FLIGHT OF EVERY DAY
600N Effectivity: RN003RN059 (Ref. SB600N039), Perform Tailboom Attach Fitting 533030
Inspection (Ref. EAD 20012451) (Not required if TB600N007R1 has been
accomplished).
EVERY 15 HOURS
369D/E/FF Effectivity: 369H1203BSC or 369H120321 leadlag link assemblies with at least 621000
500 hours, perform Main Rotor Blade Upper and Lower Root Fitting Attach Lug and
LeadLag Link Attach Lug Inspection (25 Hour) and every 100 hours in accordance
with Main Rotor Blade Upper and Lower Root Fitting Attach Lug and LeadLag Link
Attach Lug Inspection (100 Hour) until retirement of 369H1203BSC or21 LeadLag
Link Assembly. (Reference AD 950313).
25 HOURS AFTER REPLACING TAIL ROTOR DRIVE FORK HINGE BOLT
369D/E/FF Check rotational torque of bolt by applying 125 inchpounds (14.12 Nm) with torque 642010
wrench. If 125 inchpounds (14.12 Nm) torque does not rotate bolt, preload is correct 642020
(Ref. COM, Hub and Fork Assembly).
25 HOURS AFTER INSTALLATION OF OIL COOLER BLOWER
ALL With two pounds of force applied, check belt tension for 0.17 to 0.20 inch (4.32 5.08 63
mm) deflection. Check pulley (Ref. Cooling Blower Belt Tension Check and
Adjustment). Check oil cooler blower driven pulley retaining nut for minimum torque of
160 inchpounds (18.08 Nm). If loss of torque is noted, remove pulley nut and
inspect pulley shaft and splines for condition. Reinstall nut and torque to 160 190
inchpounds (18.08 21.47 Nm) plus drag torque.
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Table 1. Special Inspections Hourly (Cont.)

EVERY 25 HOURS WITH 2 FAILED LAMINATES IN MAIN ROTOR STRAP ASSEMBLY
369D/E/FF Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 25hour 622000
500N intervals if 2 laminates have failed in any one leg or tongue area of any strap
assembly. A single cracked laminate between the shoes at the outboard end of a strap
pack is cause for rejection of the hub assembly (Ref. Main Rotor Strap Pack
Lamination Inspection).
EVERY 25 HOURS WITH 1 FAILED LAMINATES IN MAIN ROTOR STRAP ASSEMBLY
600N Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 25hour 622060
intervals if 1 laminate has failed in any one leg or tongue area of any strap assembly.
A single cracked laminate between the shoes at the outboard end of a strap pack is
cause for rejection of the hub assembly (Ref. Main Rotor Strap Pack Lamination
Inspection).
EVERY 25 HOURS
NOTE: This inspection does not apply to 369D21100516, 517, 523 and 369D21102503, 517, 523 main
rotor blades or the 369H120351 and 61 leadlag links.
369D/E/FF Visually inspect exposed portion of all installed main rotor blade upper and lower root 621000
fitting attach lugs and main rotor hub leadlag link attach lugs for broken or cracked
lugs, corrosion or other damage to the lug areas (Ref. Main Rotor Blade Upper and
Lower Root Fitting Attach Lug and LeadLag Link Attach Lug Inspection (25Hour)).
EVERY 50 HOURS
369D/E/FF Effectivity: On models equipped with Rotorcraft Litter Kit: visually inspect litter doors CSP026
500N for condition and security of quickrelease fasteners. Rubber gasket between window
glass and door for proper sealing.
EVERY 50 HOURS IF CRACKS ARE FOUND IN FAN LINER
NOTE: If cracks protrude into Felt Metal Seal, replace seal.
500/600N Inspect fan liner to ensure cracks do not protrude into Felt Metal Seal (Ref. 642530
AntiTorque Fan Liner (Felt Metal Seal) Inspection).
EVERY 100 HOURS
ALL If installed, floats and associated components for condition and security. 32
ALL Effectivity: With 369F5450501 overrunning clutch installed, remove clutch assembly 63
and inspect clutch retainer, bearing carrier and housing at pin and shoulder for
evidence of spinning and/or wear. If spinning and/or wear is observed, replace clutch
assembly.
EVERY 300 HOURS
600N Replace tailboom attach bolts with new bolts, scrap removed bolts 534030
(Ref. Tailboom Installation).
Inspect radius blocks and tailboom attach points for corrosion and cracks
(Ref Tailboom Inspection).
EVERY 300 HOURS OR ONE YEAR (Whichever occurs first)
ALL Effectivity: For 369D25100 main transmission serviced with MILL23699 oil, drain 12
main transmission oil system; Flush with sufficient new oil to remove sludge
accumulation. Replace filter and refill with new oil.
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500/600N Effectivity: Forward and center cable couplings; Using a bright light and 10X 672030
magnifying glass, inspect inner coupling male and female connectors for corrosion
pitting or cracks; none allowed.
EVERY 300 HOURS OR TWO YEARS (Whichever occurs first)
600N Main rotor upper thrust bearing assembly must be relubricated every 2 years or 300 622060
hours, whichever occurs first (Ref. Main Rotor Hub Upper Bearing Grease Repack,
Inspection and Replacement).
EVERY 300 HOURS
ALL Effectivity: 369D21400503 (369D/E/FF 500/600N) or M50452 (369D/E/FF 500N) 622000
leadlag dampers with at least 4200 hours, inspect for deterioration until deterioration 622060
is sufficient to retire assembly (Ref. Main Rotor Damper and Attachments Inspection
and Main Rotor Damper Weight Loading and Extension Check).
NOTE: The following inspection does not apply to 369D25100505 and 507 transmissions.
369D/E/FF Visually inspect upper surface of main transmission output shaft assembly (ring gear 632000
carrier) for bulging or raised surfaces. Using 10X magnifying glass, inspect upper
surface of shaft for cracks. (Ref. COM, Output Drive Shaft Visual Inspection)
369D/E Replace antiice/airframe fuel filter element (if installed) (Ref. AntiIce Fuel Filter 282500
500/600N Replacement).
ALL Mist eliminator and access door for proper installation (attaching hardware for 71
security).
ALL Hoist installation (if installed) for condition and security. 25
EVERY 600 HOURS OR ONE YEAR (Whichever occurs first)
ALL Effectivity: 369D25100 main transmission serviced with Mobil SHC 626 oil and 12
369F5100 main transmission, drain main transmission oil system; Flush with sufficient
new oil to remove sludge accumulation. Replace filter and refill with new oil.
369D/E/FF Effectivity: 369F5510 Main Rotor Drive Shaft, perform 369F5510 Main Rotor Drive 631000
500N Shaft Inspection (Ref. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection).
600N Effectivity: 600N5510 Main Rotor Drive Shaft, perform 600N5510 Main Rotor Drive 631000
Shaft Inspection (Ref. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection).
EVERY 600 HOURS
ALL Cyclic control system for excessive slack or free play. Cyclic control stick, at grip, for 671000
play in excess of 3/8 inch (9.53 mm) (Ref. Main Rotor Flight Control System 600Hour
Inspection).
ALL Effectivity: 369D21400503 (369D/E/FF 500/600N) or M50452 (369D/E/FF 500N) 622000
leadlag dampers with less than 4200 hours, inspect for deterioration until 622060
deterioration is sufficient to retire assembly (Ref. Main Rotor Damper and Attachments
Inspection and Main Rotor Damper Weight Loading and Extension Check).
500/600N Using a dial indicator, measure the rotation of the fan pitch control clevis mounted on 632530
the fan pitch control tube. If clevis rotation is more than 0.025 in. (0.635 mm), inspect 672030
splines on fan pitch control tube (Ref. Fan Pitch Control Tube Inspection) and splines
in tube support (Ref. Tube Support Inspection).
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EVERY 1200 HOURS
ALL Test battery over temperature sensor unit for proper operation and accuracy (Ref. 960500
Battery Temperature Sensing Equipment Operational Check).
500/600N Perform visual inspection, using a 10x magnifying glass, on horizontal stabilizer 53
mounting brackets (pay particular attention to the forward inboard legs).
500N Regrease YSAS actuator (Ref. YSAS Actuator Regrease Procedure). 672030
600N Perform Forward Upper Longeron Inspection (L153, R153). 533030
EVERY 1200 HOURS OR 2 YEARS (WHICHEVER OCCURS FIRST)
500/600N Clean, inspect and relubricate (repack) fan support and pitch plate bearings (Ref. 642530
AntiTorque Fan Bearing Regreasing).
500/600N Perform AntiTorque Fan Inspection. 642530
500/600N Check pitch bearing retainer for cracks or damage. 64
600N Main rotor lower thrust bearing assembly must be relubricated every 2 years or 2700 622060
hours, whichever occurs first.
600N Clean, inspect and relubricate (repack) main rotor swashplate bearings. 623060
369D/E/FF Clean, inspect and relubricate (repack) main rotor swashplate bearings and main rotor 622000
500N hub tapered bearings (Ref. Main Rotor Hub Tapered Bearing Replacement).
369D/E/FF Clean, inspect and relubricate (repack) tail rotor swashplate bearings (Ref. Tail Rotor 643000
Swashplate Bearing Regreasing).
EVERY 6,000 HOURS
DELETED
AT 6000 HOURS AND EVERY 100 HOURS THEREAFTER
600N Remove tunnel control boot. Inspect interface between 369H2564 tunnel beams and 533030
369D225087 web for cracks (Ref. Control Tunnel (FS 78.50) Beam Inspection).
600N Effectivity: (RN003RN077 with TB600N007 completed, and RN078 and subs) 533030
Perform Forward Upper Longeron Inspection (L137, R137).
AT 15,000 HOURS AND EVERY 1500 HOURS THEREAFTER
600N Effectivity: (RN003RN077 with TB600N007 completed, and RN078 and subs) 533030
Perform Lower Longeron Inspection (L158, R158).
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Table 2. Special Inspections Calendar

Model What to Inspect Section
(DAILY) BEFORE FINAL SHUTDOWN IN CORROSIVE ENVIRONMENT
ALL It is recommended that before shutdown from the last flight of the day, for helicopters 204000
operating in a corrosive environment, a TriFlow wash be preformed on the main
rotor hub and strap pack assembly (Ref. Main Rotor Hub Corrosion Prevention
(TriFlow Wash Procedure)).
(DAILY) AFTER FINAL SHUTDOWN IN CORROSIVE ENVIRONMENT
500N It is recommended that after shutdown from the last flight of the day, for helicopters 20
operating in a corrosive environment, the splitter bungee spring be sprayed with
TriFlow.
EVERY 6 MONTHS OR 5 INFLATIONS
ALL Inflate emergency floats to 4.5 psi (0.3164 kg/cm2) for one hour. Check for leaks and 328200
condition. Continue inflation to 5.5 psi (0.3867 kg/cm2) and check that chamber
pressure relief valves operate. Pressuretest float compartments (Ref. Float
Compartments Pressure Test).
AFTER COMPRESSOR WATER WASH/RINSE WITH PARTICLE SEPARATOR INSTALLED
ALL During engine run after compressor water wash with particle separator installed, it is RFM
recommended that scavenge air switch be switched on to remove any moisture that
has accumulated in the solenoid air valve.
BEFORE OPERATION OF BREEZE HOIST SYSTEM
ALL Prior to daily hoisting operations: unreel and inspect entire length of hoist cable for 01
broken strands (cluster of 7 wires), excessive broken wires, corrosion, and security of
attachment to cable drums and swivel hook. Replace cable if broken strand or
excessive broken wires are noted. (Refer to hoist manufacturers handbook, Table
201.)
AFTER FIRST FLIGHT WITH NEW EXHAUST GASKET INSTALLED
369FF/600N Exhaust bolts should be retorqued after first flight. If bolts are found to be 783000
loose, retorque after every flight until bolts retain torque.
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Section
055000
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Airworthiness
MAINTENANCE MANUAL
CONDITIONAL INSPECTIONS
1. General which the helicopter hits the ground with
sufficient force to cause:
This section contains the unscheduled or
conditional inspections. You must do the
necessary Maintenance Manual specific D main rotor blade to hit the tailboom or upper
inspections and procedures shown in Table 1 to fairings or cowlings.
make sure there is continued airworthiness of
the helicopter.
D permanent deformation of the landing gear
If there is an incident with your helicopter not more than permitted limits.
shown in this section, record all information
regarding the incident and speak to the Field
Service Department at MDHI, Mesa, Arizona. D the lower fuselage, lower tailboom surface,
Telephone 18003883378 or (480) 3466387. tailrotor, or thruster to touch the ground.
DATAFAX: (480) 3466813 for inspections and
maintenance procedures you need to do.
Use the schedule of inspections in Table 1,
It is possible you will need to do more than one Conditional Inspections, After Hard Landing if
of the inspections or procedures shown in you think a hard landing has occurred.
Table 1 of this section. Do all inspections that
are applicable.
3. Overspeed
NOTE: Refer to the applicable RollsRoyce En-
gine Operation and Maintenance Manual
(Ref. Section 010000, Table 201) for de- Overspeed is an incident in which the rotor
tailed requirements on inspection of the en- speed (NR) is more than the limits shown in
gine for specific or unique conditions compa- the applicable Rotorcraft Flight Manual. Use
rable to those listed. the schedule of inspections in Table 1, Condi-
tional Inspections, After Main Rotor Over-
WARNING speed when an overspeed has occurred.
D All components, assemblies, or parts

that are removed for overhaul or re- 4. Overtorque
pair must be identified with the
cause for removal.
Overtorque is an incident in which the main
D All other components, assemblies, or
transmission torque loads are more than the
parts that need to be replaced, must
permitted limits. Use the schedule of inspec-
be discarded.
tions in Table 1, Conditional Inspections, After
2. Hard Landing Main Transmission Overtorque Beyond
Transient Limits when an overtorque has
A hard landing is an incident or accident in occurred.
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5. Sudden Stoppage when sudden stoppage of the tail rotor has

occurred.
Sudden stoppage is a rapid deceleration of the
main rotor, rotor drive system, tail rotor, or 6. Lightning Strike
antitorque fan.
When you think there has been a lightening
Sudden stoppage of the main rotor and rotor strike on the helicopter, use the schedule of
drive system is caused when the main rotor inspections in Table 1, Conditional Inspec-
blades hit the ground, water, snow, thick tions, After Lightening Strike inspection
vegetation, or other object of sufficient mass to procedures.
cause deceleration. Sudden stoppage of the
main rotor and rotor drive system can also 7. Conditional Inspection Table
occur during a hard landing if the blades hit D Inspections in this table are for MDHI
the fuselage or the tailboom. Use the schedule 369D/E/FF and 500/60N helicopters only.
of inspections in Table 1, Conditional Inspec- The first column of the table denotes which
tions, After Main Rotor Blade/Drive System model helicopter the inspections are
Sudden Stoppage when sudden stoppage of the applicable to.
main rotor has occurred.
D The second column of the table has a short
Sudden stoppage of the tail rotor is caused description of the necessary inspection or
when the tail rotor blades hit the ground, procedure.
water, snow, thick vegetation, or other object of
sufficient mass to cause deceleration. Use the D The third column of the table shows, if
schedule of inspections in Table 1, Conditional applicable, the manual or section that has
Inspections, After Tail Rotor Blade Strike the specific inspection or procedure.
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Table 1. Conditional Inspections

Model Requirement Chap/Sect
AFTER HARD LANDING
WARNING: Any component, assembly or detailed part that is removed for overhaul must be identified as
to the reason for removal. Components that require replacement must be discarded.
ALL Main rotor blades for bending, cracks or wrinkles. 62
ALL Main rotor blade droop stops for damage. 62
ALL Main rotor hub assembly and strap pack assembly for evidence of damage. 62
ALL Accessible areas of main rotor mast assembly and transmission attachment area for 63
damage.
ALL Perform Landing Gear Inspection. Forward and aft rub plates for condition. 321000
ALL Perform Tailboom Inspection; retorque mount bolts. 534000
534030
ALL Inspect tailboom attachment area for damage. 53
500/600N Inspect stationary thruster attachment flange for damage; retorque mount bolts. 53
369D/E/FF Tail rotor drive shaft and damper, tail rotor transmission and tail rotor for distortion, 63
loose mounting or attaching parts, buckling, breaks or other damage. Tail rotor drive 64
shaft for contact with bulkheads.
500/600N Main transmissiontofan transmission drive shaft, fan transmission, fan drive shaft, 63
fan and fan control rod for distortion, loose mounting or attaching parts, buckling, 67
breaks or other damage. Drive shafts for contact with bulkheads.
Fan control rod for freedom of movement.
ALL Perform Engine Mounts and Fittings Inspection. Inspect mounting pads and firewall for 71
damage and distortion. Inspect all suspected parts by magnetic particle or
dyepenetrant methods, as applicable (Ref. CSPSRM6).
ALL All flight and engine control system pushpull tubes, links, bellcranks and bearings for 67
bends, cracks, security and free movement.
ALL Tunnel area Aframe for distortion, buckling or any other damage. 53
ALL Fuselage fittings for bends and cracks. 53
ALL Main transmission chip detectors for metal particles. 63
Main transmission mounting flanges for cracks.
ALL Perform Main Transmission Drive Shaft Inspection. 631000
ALL All engine accessories for cracked flanges, loose bolts and nuts, connections and 79
general condition.
ALL Engine accessory drive housing for cracks. 79
ALL Engine chip detectors for metal particles. 79
ALL Engine oil tank, supports, tubing and hoses for leaks, cracks and security. 79
ALL Fuel cells, supports, tubing and hoses for leaks, cracks and security. 28
ALL Armor for security of attachment, buckling and distortion. CSP014
ALL Rotor brake installation for security of attachment and disc alignment. 63
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Table 1. Conditional Inspections (Cont.)

AFTER MAIN ROTOR OVERSPEED
to the reason for removal. Components that require replacement must be scrapped.
If overspeed is between 523 and 549 (369D/E) or 508 and 533 (369FF, 500N) rpm, or 106 and 112 percent
(600N):
ALL Main rotor blades for visible damage and distortion; main rotor blade tip caps for 62
security; all bond lines for evidence of separation; root doublers and attachment
fittings for security. Replace any blade with visible bond line separation.
Main rotor blade dampers for security.
369D/E/FF Tail rotor blades and hub for visible damage, free movement and security. 64
500/600N NOTAR fan blades and hub for visible damage, free movement and security. 64
ALL Main rotor hub and strap pack assembly for evidence of damage. 62
If overspeed is over 549 (369D/E) or 533 (369FF, 500N) rpm, or 112 percent (600N):
ALL Remove main rotor hub assembly for overhaul inspection. MDHI
ALL Remove and scrap main rotor blades. 62
500/600N Inspect antitorque fan assembly. 64
369D/E/FF Remove tail rotor hub assembly for overhaul inspection. 64
AFTER MAIN TRANSMISSION OVERTORQUE BEYOND TRANSIENT LIMITS
ALL Main transmission for freedom of movement. 63
ALL Main transmission chip detectors for metal particles. Reinspect after 8 hours of 63
operation.
AFTER AIRSPEED 10% BEYOND VNE LIMIT
ALL Main rotor blades for visible damage and distortion; main rotor blade tip caps for 62
security; all bond lines for evidence of separation; root doublers and attachment
fittings for security. Replace any blade with visible bond line separation.
Main rotor hub assembly and strap pack assembly for evidence of damage.
Main rotor blade dampers for security.
369D/E/FF Tail rotor blades and hub for visible damage, freedom of movement and security. 64
369D/E/FF Horizontal stabilizer for skin damage and loose rivets. 53
Tip plates and vertical stabilizer for damage to leading and trailing edges and
damaged stressed side panels (no repair of side panels permitted).
Mounting fittings for cracks and security.
Retorque stabilizer attach bolts.
500/600N Horizontal stabilizer for skin damage and loose rivets. 53
600N Damage to gurney flap.
Vertical stabilizers for damage to leading and trailing edges and damaged side panels.
Mounting fittings for cracks and security.
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ALL Tailboom for visible deformation, loose or missing rivets, cracks and security; attaching 53
points to fuselage for cracks and security.
ALL Canopy glass for security 53
AFTER MAIN ROTOR BLADE/DRIVE SYSTEM SUDDEN STOPPAGE
Sudden stoppage of the main rotor and rotor drive system is any rapid deceleration of the main rotor drive
system. This may be caused by contact of one or more of the main rotor blades with the ground, water, snow,
dense vegetation or any other object of sufficient mass to cause deceleration or impact damage to the main
rotor blades.
A main rotor blade strike in which one or more of the main rotor blades exceed the repair limits in the
maintenance manual is defined as sudden stoppage.
Sudden stoppage of the main rotor may also occur simultaneously with hard landing in which the blades contact
the upper fuselage structure or the tailboom.
The inspection requirements, After Main Rotor Drive System Sudden Stoppage Level 1, is to be used when
sudden stoppage of the main rotor drive system has occurred.
After Main Rotor Drive System Sudden Stoppage Level 1
ALL Perform inspection of main rotor blades. Pay particular attention to the upper and 62
lower root fittings and attach lug areas. If inspection determines that one or more
blades have separation of the trailing edge bond, due to leading edge impact, the
blade is bent or shows evidence of a significant impact, and the damage occurred with
the engine running, perform the additional inspection in After Main Rotor Drive System
Sudden Stoppage Level 2.
ALL Perform inspection of the main rotor hub and leadlag link attach lugs. If the leadlag 62
lug is broken or the pitch housing striker strip shows evidence of contact with the main
rotor hub and damage occurred the the engine running, perform the additional
inspection in After Main Rotor Drive System Sudden Stoppage Level 2.
ALL Perform Main Rotor Strap Pack Lamination Inspection. 622000
622060
ALL Perform Main Rotor Blade and Damper Attach Pin Disassembly and Special 621000
Inspection. If a pin is found cracked or bent and damage occurred with the engine
running, perform the additional inspection in After Main Rotor Drive System Sudden
Stoppage Level 2.
ALL Perform Main rotor Damper and Attachments Inspection. If damage to a damper is 622000
suspected, perform Main Rotor Damper Weight Loading and Extension Check. 622060
ALL Perform Main Rotor Drive Shaft Inspection. If main rotor drive shaft is rejected for 631000
broken shaft splines, straightness or sheared shaft, perform the additional inspection
in After Main Rotor Drive System Sudden Stoppage Level 2.
ALL Inspect overrunning clutch sprag assembly (Ref. Detailed Inspection after Cleaning). COM
CAUTION: Kamatic couplings are a balanced unit and cannot be disassembled.
ALL Perform a visual inspection of all power train drive shafts and couplings for distortion, 63
breaks, cracks, contact with bulkheads and other damage.
ALL Perform a visual inspection of the oil cooler blower assembly. 63
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ALL Check main rotor transmission for freedom of movement. Visually check main rotor 63
transmission mounting flanges for cracks. Inspect main rotor transmission chip
detectors for metal accumulation. Reinspect chip detectors after eight hours of
helicopter operation.
ALL Perform visual inspection of main rotor flight controls. 67
ALL Perform visual inspection of the antitorque system. 64
ALL Perform visual inspection of engine mounts for security, cracks or misalignment. 71
ALL Perform visual inspection of the engine control linkage for bends, breaks and proper 76
alignment.
ALL Inspect engine per the special inspection requirements in the appropriate Allison 01
Operation and Maintenance Manual.
After Main Rotor Drive System Sudden Stoppage Level 2
being removed due to Main Rotor Sudden Stoppage Level 2. Components that require replacement
must be scrapped.
ALL Overhaul main rotor hub. 62
ALL Remove and scrap main rotor drive shaft. 63
ALL Overhaul main transmission assembly (Ref. COM). 63
ALL Remove and scrap enginetotransmission drive shaft. 63
ALL Overhaul overrunning clutch assembly (Ref. COM). 63
AFTER TAIL ROTOR BLADE STRIKE
After tail rotor blade strike, inspect the following:
369D/E/FF If equipped with Bendix couplings, remove and scrap couplings. 63
369D/E/FF Tail rotor blades for dents, nicks, scratches or separation of skin. 64
369D/E/FF Tail rotor flapping hinge bolt for damage. 64
369D/E/FF Tail rotor transmission for radial play and runout of output shaft, cracks in mounting 63
flanges, and chip detector for metal particles.
Remove for overhaul tail rotor transmission if damage is indicated.
369D/E/FF If equipped with Kamatics couplings: 631510
Perform Tail Rotor Drive Shaft Twist Inspection. Misaligned or missing stripes require 632510
removal and scrapping of drive shaft and Kamatics couplings, and an overhaul 632520
inspection of tail rotor transmission (Ref. COM).
369D/E/FF Remove tail rotor drive shaft and inspect couplings for distortion and cracks; damper, 63
damper bracket and bulkheads for damage.
NOTE: If damage in excess of allowable limits due to blade strike is noted in above areas, continue with following
inspections:
369D/E/FF Tail rotor drive fork, pitch links, swashplate, hub and pitch control bearing housing for 64
obvious damage.
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369D/E/FF Upper fuselage and boom tail rotor control linkage. 67
If tail rotor control rod is damaged, ensure that all rod bulkhead grommets are in
place.
369D/E/FF Aft frame of tailboom for cracks and boom skin for loosened or popped rivets. 53
369D/E/FF Main transmission chip detectors and transmission lube pump oil filter for metal 63
particles.
369D/E/FF Main rotor hub assembly and strap pack assembly for evidence of damage. 62
AFTER TAILBOOM STRIKE
If one or more main rotor blades strike tailboom while blades are rotating, inspect following:
ALL Perform Main Rotor Blade Inspection. 621000
ALL If excessive damage requires replacement of main rotor blade(s), inspect complete 62
main rotor and scissors assembly, including droop stop mechanism and strap packs,
for evidence of damage.
369D/E/FF Remove and inspect tail rotor drive shaft for impact damage, buckling or twisting; 63
couplings for cracks and distortion; damper, damper bracket and bulkheads for
damage.
369D/E/FF If excessive damage requires replacement of tail rotor drive shaft, replace couplings 63
and perform overhaul inspection of tail rotor transmission (Ref. COM).
CAUTION: Any tailboom damage is significant (Ref. CSPSRM6).
ALL Perform Tailboom Inspection. Dyecheck or remove and scrap tailboom attach bolts. 534000
534030
ALL Structure forward of tailboom attachment for evidence of sheet metal yielding or 53
buckling. Pay particular attention for signs of buckling at right side forward of tailboom
attachment (Ref. CSPSRM6).
ALL Perform Upper Fuselage and Tailboom Control Linkage Inspection. 67
ALL Perform Horizontal Stabilizer Inspection. 535010
Perform Vertical Stabilizer Inspection. 535030
369D/E/FF Tail rotor assembly. 64
369D/E/FF Tail rotor transmission for radial play and runout of output shaft; cracks in mounted 64
flanges and chip detector for metal particles.
ALL Main rotor brake, if installed, for condition and alignment of brake disc, calipers and 63
If tailboom strike occurred during POWER ON condition, also inspect the following:
ALL Remove and inspect main rotor drive shaft, main transmission drive shaft and 63
couplings for distortion, breaks, cracks and other damage.
ALL Main transmission chip detectors and transmission lube system oil filter for metal 63
particles. Reinspect chip detectors and oil filter after 8 hours of engine operation.
Visually check transmission mounting flanges for cracks.
Page 7
055000 Revision 42
MAINTENANCE MANUAL

ALL Engine air inlet and plenum chamber for foreign objects; motor engine and check for 71
unusual noise. 76
Engine mounts for security, cracks or distortion.
Engine control linkage for bends, breaks and proper operation.
500/600N Inspect stationary thruster attachment flange for damage; retorque mount bolts. 53
ALL Inspect tailboom attachment area for damage; retorque mount bolts. 53
AFTER CHIP DETECTOR LIGHT COMES ON
ALL Remove chip detector leads, in turn, to determine which chip detector caused indicator 63
to light. 71
Remove and inspect applicable chip detector for metal accumulation.
ALL If an engine chip detector caused indicator to light, refer to applicable Allison Engine 01
ALL If main transmission chip detector caused indicator to light, perform Main 632100
Transmission Filter Replacement.
ALL If chips measure no longer than 0.125 inch (3.175 mm), drain and refill main and/or 12
fan transmission with new oil. Recheck applicable chip detectors after 4 hours of flight.
AFTER ENGINE CHANGE BECAUSE OF INTERNAL ENGINE FAILURE
NOTE: Oil coolers are NOT cleanable and must be scrapped if an engine failure produces metal and NO scav-
enge oil filter is installed or if a scavenge oil filter is installed and indicates a bypass has occurred.
ALL Remove, flush and reinstall oil tank. 12
Flush all lines, fittings and associated components. 79
Remove and reverse flush or replace engine oil cooler.
CAUTION: Failure to bleed fuel system can result in unexpected engine flameout or power loss.
ALL Bleed fuel system. 28

ALL Remove and install new scavenge oil filter element (if installed). 79
AFTER ENGINE FLAMEOUT CAUSED BY FUEL EXHAUSTION
ALL Bleed fuel system to remove any entrapped air. 28
AFTER ENGINE SHUTDOWN USING EMERGENCY FUEL SHUTOFF VALVE
ALL Bleed fuel system to remove any entrapped air. 28
AFTER MAIN TRANSMISSION CHANGE BECAUSE OF INTERNAL TRANSMISSION FAILURE
ALL Reverse flush or replace transmission oil cooler, all lines, fittings and associated 63
components.
AFTER FUEL FILTER CAUTION LIGHT COMES ON
ALL Check FUEL FILTER caution light and circuit for discrepancies. 95
ALL Perform Fuel Filter (Bypass) Caution Light Pressure Switch Test. 280000
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Revision 42 055000
MAINTENANCE MANUAL

ALL Remove and install new enginedriven fuel pump filter. 01
Remove and clean gas producer fuel control filter.
Clean and flush all lines and fittings.
Check bypass valve per applicable Allison Engine Operation and Maintenance
Manual.
369D/E Inspect start pump inlet screen for contamination when large amounts of foreign 28
500N material are found in the engine driven fuel pump filter (or optional airframe fuel filter, if
installed).
ALL Perform Fuel Cell Inspection. 280000
AFTER NEW OR REPLACEMENT MAIN ROTOR HUB IS INSTALLED
ALL Perform Main Rotor Hub Droop Angle Check. 622000
BEFORE INSTALLATION OF NEW BATTERY
ALL Perform Battery Charging Deep Cycling Procedure. Repeat deep cycling procedure 960500
once to ensure complete stabilization of battery.
AFTER MAIN TRANSMISSION DRIVE SHAFT IS REMOVED (ENGINE INSTALLED)
ALL Check overrunning clutch for correct oil level. 12
AFTER COOLER BLOWER IS REMOVED
ALL Perform Cooling Blower Inspection (Disassembled). Check belt tension and clearance 63
after installation.
WHEN MAIN ROTOR DRIVE SHAFT IS REMOVED
ALL Perform Main Rotor Drive Shaft Inspection. 631000
AFTER LIGHTNING STRIKE
If lightning strike is evident on helicopter exterior:
ALL Inspect the fuselage interior and exterior, landing gear, rotor systems and ground wire 25
connection for burn marks, cracks, pitting or other signs of high temperature stress, to 32
determine the lightning entry and exit points. 53
ALL Trace the path of the lightning strike to the extent possible using a magnetometer.
ALL Check the magnetic compass for accuracy (the degree of inaccuracy may serve as an 95
indicator of the severity of the strike).
ALL Inspect all wiring. 96
ALL Inspect antenna(s) for burns and pitting. 97
ALL Inspect all electrically operated components and lighting systems for damage. 96
ALL Inspect communications and navigation equipment for damage. 97
ALL If the preceding inspections reveal major damage has occurred, proceed as follows: 96
Bench test all avionics and electrical system and components. 97
Perform a continuity check on all wiring and cables.
Perform a Voltage Standing Wave Ratio (VSWR) check on all antennas, antenna
cables and connectors.
Page 9
055000 Revision 42
MAINTENANCE MANUAL

ALL Perform specific inspection/replacements as required.
500/600N Check fan transmission and interconnecting drive shafts for magnetism and/or burns. 63
500/600N If previous drive train items show magnetism, overhaul fan transmission. COM
500/600N Inspect antitorque fan and components for evidence of arcing and magnetism; 64
replace any part showing evidence of arcing or magnetism.
500/600N Inspect bellcrank and control rod for any indications of arcing. Scrap parts with 67
indications of arcing.
500/600N Inspect thruster cables, bellcranks and control tubes for any indications of arcing. 67
Scrap parts with indications of arcing.
500/600N Inspect thruster rollers for any indications of arcing. Scrap parts with indications of 53
arcing.
ALL Check oil cooler blower assembly and overrunning clutch for residual magnetism;
replace as necessary.
ALL Inspect oil cooler assembly for damage; replace as necessary.
ALL If previous drive train items show magnetism, overhaul transmission.
ALL If overrunning clutch assembly shows magnetism, remove engine and overrunning
clutch and overhaul.
ALL Perform a ground run operational check on the aircraft. Functionally check the flight 67
control system, and all avionics, electrical, lighting, communication, and navigation 96
systems. 97
ALL Repair any damage and replace damaged components as required.
If lightning strike is evident on main rotor system:
ALL Inspect blades for damage such as burns, pitting, skin separation, etc. If damage is 62
evident, scrap damaged blade(s).
ALL Remove hub assembly and return for overhaul. 62
ALL Inspect all bearings in the fixed and rotating control system located on the main rotor 62
mast.
ALL Remove transmission assembly and overhaul. 63
ALL Inspect main rotor mast and drive shaft for evidence of burns. 63
ALL Check drive shafts for residual magnetism. If magnetized or damaged, scrap drive 63
shafts and remove engine for overhaul. 71
If lightning strike is evident on tail rotor system:
369D/E/FF Inspect blades for damage such as burns, pitting, skin separation, etc. If damage is 64
evident, scrap damaged blade(s).
369D/E/FF Overhaul tail rotor assembly. COM
369D/E/FF Scrap pitch change links and pitch change assembly. 64
369D/E/FF Inspect bellcrank and control rod for any indications of arcing. Scrap parts with 67
indications of arcing.
369D/E/FF Overhaul tail rotor gearbox. COM
369D/E/FF Inspect tail rotor drive shaft and drive shaft damper for magnetism and/or burns. 63
Page 10
Revision 42 055000
MAINTENANCE MANUAL

369D/E/FF Check oil cooler blower assembly, overrunning clutch and tail rotor drive shaft 63
couplings for residual magnetism; replace as necessary.
369D/E/FF Inspect oil cooler assembly for damage; replace as necessary. 63
369D/E/FF If previous drive train items show magnetism, overhaul transmission. COM
369D/E/FF If overrunning clutch assembly shows magnetism, remove engine and overrunning 71
clutch and overhaul. COM
369D/E/FF Inspect engine mounts and fitting for damage. Replace as necessary. 71
AFTER 369F5100 MAIN TRANSMISSION LUBRICATION PUMP IMPENDING BYPASS INDICATOR POPS
ALL Refer to Troubleshooting Power Train System 630000
WHENEVER ENGINE IS REMOVED
ALL Remove fire blanket from above engine and inspect airframe above engine for 53
evidence of cracks.
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MAINTENANCE MANUAL
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Revision 42 055000
MAINTENANCE MANUAL
Chapter
06
Dimensions and
Areas
MAINTENANCE MANUAL
TABLE OF CONTENTS
060000 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Principal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Airframe Stations Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Principal Dimensions Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Principal Dimensions Models 369E . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Principal Dimensions Model 369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 204. Principal Dimensions Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 205. Principal Dimensions Model 600N (Sheet 1 of 2) . . . . . . . . . . . . . . . 206
Figure 206. Station Diagram Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 207. Station Diagram Models 369E/FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 208. Station Diagram Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 209. Fuselage Station Diagram Model 600N . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 210. Aft Empenage Access Plugs Model 600N . . . . . . . . . . . . . . . . . . . . . . 212
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
060000
Dimensions and
Areas
MAINTENANCE MANUAL
DIMENSIONS AND AREAS

1. Principal Dimensions cm) forward of the fuselage nose for
Models 369E/FF. WL 0.00 is tangential
(Ref. Figure 201 for Model 369D, to bottom of fuselage at STA 90.61.
Figure 202 for Model 369E, Canted stations start at WL 0.00 unless
Figure 203 369FF, otherwise specified. The canted station
Figure 204 for 500N and is not the same distance from STA 0.00
Figure 205 for 600N) over its length, and should be referred
to in association with a waterline
2. Airframe Stations Locations reference.
(1). Reference is occasionally made to (3). For the 600 Series Helicopter, all
Fuselage Station (STA or FS), Fuselage dimensions are from three reference
Station Plug (P. STA or FSP) and points designated as STA 0.00, P. STA
Waterline (WL) throughout the manual. 0.00 and WL 0.00 for the fuselage/engi-
P. STA or FSP refers to the stretched neering station references. STA 0.00 is
area or longer fuselage section of the 15.00 inches (38.1 cm) forward of the
600N as compared to the 500 Series fuselage nose. P. STA 0.00 is located at
Helicopter. Fuselage Station and the forward lower edge of the mid door
Waterline are the same as those (also designated as canted STA 78.50).
referred to in the other 500 Series All references outside of the designated
publications. To assist in locating P. STA areas are labeled STA or FS.
components being discussed, station Waterline 0.00 is tangential to bottom
diagrams are provided (Ref. Figure 206 of fuselage at fuselage station STA
for Model 369D, Figure 207 for Models 90.61. Canted stations start at water-
369E/FF, Figure 208 for 500N and line 0.00 unless otherwise specified.
Figure 209 for 600N). Station and The canted station is not the same
Waterline references are also necessary distance from WL 0.00 over its length,
for weight and balance procedures (Ref. and should be referred to in association
Sec. 081000). with a waterline reference.
(2). For the 500 Series Helicopters, all (4). Measurements from a station repre-
dimensions are from two reference sented by a rib, frame, or bulkhead that
points designated as STA 0.00 and WL is not accessible may be taken by noting
0.00. STA 0.00 is 28.00 inches (71.12 flange bend direction and compensating
cm) forward of the fuselage nose for on the correct side of visible external
Model 369D, and 15.00 inches (38.10 skin attachment rivet line.
Page 201
060000 Revision 23
MAINTENANCE MANUAL
GENERAL NOTES:
1. HELICOPTER ON GROUND, MAX.
COMPRESSED DIMENSION: 6.8 IN.
(17.272 CM).
2. IF OPTIONAL EXTENDED LANDING
GEAR IS INSTALLED, ADD 0.63 FT.
8.2 FT. 7.2 FT (10.19 M) TO ALL VERTICAL DIMENSIONS.
(2.5 M) (2.2M)
0.76 FT
(0.23 M)
26.41 FT (8.06 M)
6.45 FT. 5.46 FT.

4.57 FT.
(1.97 M) (1.67 M)
(1.39 M)
13.205 FT. (4.028 M)
31.31 FT. (9.55 M)

30.84 FT. (9.41 M)
22.53 FT. (6.72 M)
6.002 FT. (1.831 M) 15.208 FT. (4.64 M)
8.9 FT.
(2.7 M)
4.58 FT.
7.67 FT. (1.40 M)
(2.34 M) 6.3 FT.
(1.9 M)
1.58 FT. (0.48 M)
21.21 FT. (6.50 M) 2.29 FT. (0.70 M)

23.5 FT. (7.2 M)
G060001B
Figure 201. Principal Dimensions Model 369D
Page 202
Revision 23 060000
MAINTENANCE MANUAL
GENERAL NOTES:
1. HELICOPTER ON GROUND WITH FULL
FUEL. TYPICAL ATTITUDE OF CARGO
DECK 4.7 DEGREES NOSE UP.
8.72 FT. 2. IF OPTIONAL EXTENDED LANDING GEAR
(2.66 M) IS INSTALLED, ADD 0.87 FT. (0.27 M) TO
ALL VERTICAL DIMENSIONS.
7.65 FT.
(2.33 M)
1.27 FT.
(0.39 M)
30.81 FT. (9.40 M)

6.43 FT. (1.96 M)
23.88 FT. (7.28 M)
8.15 FT.
(2.49 M) 8.4 FT.
(2.6 M)
6.77 FT.
4.58 FT.
(2.06 M)
(1.40 M)
22.42 FT. (6.84 M)

2.0 FT. (0.61 M)
24.71 FT. (7.54 M)
G060002B
Figure 202. Principal Dimensions Models 369E
Page 203
060000 Revision 23
MAINTENANCE MANUAL
GENERAL NOTES:
1. HELICOPTER ON GROUND WITH FULL FUEL.
TYPICAL ATTITUDE OF CARGO DECK 5.3
DEGREES NOSE UP.
2. IF OPTIONAL EXTENDED LANDING GEAR IS
INSTALLED, ADD 0.87 FT. (0.27 M) TO ALL
VERTICAL DIMENSIONS.
7.53 FT
8.6 FT. (2.30 M)
(2.62 M)
1.15 FT
(0.35 M)
4.57 FT. 5.43 FT.

(1.40 M) (1.66 M)
6.45 FT.
(1.97 M)
27.35 FT.
(8.34 M)
32.06 FT. (9.78 M)

6.8 FT. (2.1 M)
23.88 FT. (7.28 M)
8.1 FT
(2.5 M).
8.03 FT.
(2.45 M)
4.57 FT.
(1.39 M) 4.75 FT.
(1.45 M)
23.08 FT. (7.04 M)

25.46 FT. (7.77 M) 1.3 FT. (0.40 M)
G060003B
Figure 203. Principal Dimensions Model 369FF
Page 204
Revision 23 060000
MAINTENANCE MANUAL
GENERAL NOTES:
TYPICAL ATTITUDE OF CARGO DECK: 4.7 DEGREES
8.8 FT. NOSE UP.
(2.7 M) 2. IF EXTENDED LANDING GEAR IS INSTALLED, ADD
0.87 FT. (0.27 M) TO ALL VERTICAL DIMENSIONS.
7.7 FT.
(2.3 M)
27.35 FT.
(8.34 M)
6.3 FT.
(1.9 M)
4.6 FT. 6.5 FT.
(1.4 M) (2.0 M)
31.39 FT. (9.6 M)

24.9 FT. (7.6 M)
7.7 FT.
6.9 FT. (2.3 M)
(2.1 M)
1.4 FT.
(0.4 M)
G060006B
Figure 204. Principal Dimensions Model 500N
Page 205
060000 Revision 23
MAINTENANCE MANUAL
27.5 FT
DIA
(8.4 M)
6.6 FT
(2.0 M)
8.8 FT 4.6 FT
(2.7 M) (1.4 M)
36.9 FT
(11.3 M)
29.6 FT
(9.0 M)
9.7 FT
(2.9 M)
9.2 FT 7.8 FT 9.8 FT
(2.8 M) (2.4 M) (3.0 M)
2.4 FT
(0.7 M)
GENERAL NOTES:
TYPICAL ATTITUDE OF CARGO DECK 5.3 DEGREES NOSE UP.
2. HEIGHT ABOVE GROUND DIMENSIONS VARY WITH INSTALLED
EQUIPMENT, CENTER OF GRAVITY AND TERRAIN FEATURES.
3. ALL DIMENSIONS SHOWN DEPICT EXTENDED LANDING GEAR.
6G06043D
Figure 205. Principal Dimensions Model 600N (Sheet 1 of 2)
Page 206
Revision 39 060000
MAINTENANCE MANUAL
48 INCHES
(122 CM)
25 INCHES
(63 CM)
48 INCHES
(122 CM)
62 INCHES
(157 CM)
72 INCHES
(183 CM)
6G06038
Figure 205. Principal Dimensions Model 600N (Sheet 2 of 2)
Page 207
060000 Revision 23
MAINTENANCE MANUAL
CANT STA STA STA STA

78.50 146.62 164.87 185.89
CL CANT STA STA STA STA
124.00 137.50 155.75 174.00 CANT STA
MAST 197.78
STA
28.00
WL
WL 45.36 49.37
CORNER CL BEAM
WL PILOTS
SEAT WL
38.64 JACKING WL
WL 21.50 32.00
POINT 34.50
STA 96.89
WL WL 11.98
22.75
WL WL
14.19 13.10
WL
WL
0.00
0.00
STA STA STA STA STA STA STA

STA
44.65 56.85 84.79 96.42 108.04 119.67 137.50
0.00 STA STA CANT STA STA STA STA STA
50.50 64.37 78.50 90.61 102.23 113.85 124.00
WL
96.91
WL WL
55.34 54.17
CANT STA
209.78
CANT STA CANT STA CANT STA CANT STA
197.78 219.96 242.14 264.32
WL
CANT STA 26.67
273.00
CANT STA
281.12
NOTE: FRAME BASE
WHEN MEASURING EXTERNALLY FROM RIVET LINES,
NOTE THE SIDE AT BULKHEAD OR FRAME INDICATED AS
THE STATION AND COMPENSATE FOR RIVET POSITION
IN THE ATTACHMENT FLANGE.
G060004B
Figure 206. Station Diagram Model 369D
Page 208
Revision 23 060000
MAINTENANCE MANUAL
CANT STA
78.50
STA
108.50 STA STA STA
146.62 164.87 185.89
CL CANT STA STA STA STA
124.00 137.50 155.75 174.00 CANT STA
MAST
197.78
WL 76.70
WL 66.00
STA
15.00
WL
CORNER WL 45.36 49.37
PILOTS CL BEAM
SEAT WL 34.50
WL 21.50 WL 32.00
WL 22.75 WL 11.98
WL 14.19 WL 13.10
JACKING POINT
STA 96.89, BL 25.60
WL 0.00 WL 0.00
STA STA STA STA STA STA STA

STA 44.65 56.85 84.79 96.42 108.04 119.67 137.50
STA STA STA STA STA
0.00
50.50 64.37 90.61 102.23 124.00
CANT STA STA
78.50 113.85
WL 102.17
WL 96.91
STA 289.12 (369FF)
WL 55.34 WL 54.17
CANT STA
209.78 CANT STA 369FF ONLY
CANT STA CANT STA CANT STA 264.32
197.78 219.96 242.14
WL 26.67
CANT STA WL 25.46 (369E)
273.00 WL 22.36 (369FF)
CANT STA
281.12
NOTE:
FRAME BASE
G060005B
Figure 207. Station Diagram Models 369E/FF
Page 209
060000 Revision 23
MAINTENANCE MANUAL
STA
129.00
STA
132.90
STA
155.75
STA
STA STA
124.75
146.62 168.20
STA STA
137.50 CANT 174.00
CL
MAST STA
159.97
WL 66.00
STA WL 60.00
15.00
WL 34.50
WL 22.75
WL 14.19 WL 13.10
JACKING POINT
STA 96.89, BL 25.60
WL 0.00 WL 0.00
STA STA STA 96.42 STA STA STA

44.65 56.85 84.79 STA 108.04 119.67 137.50
STA
0.00 STA STA CANT STA STA 102.23 STA STA
50.50 64.37 78.50 90.61 STA 113.85 124.00
STA
AFT JACKING 315.00
POINT STA 275.40,
NOTE: BL 0.00, WL 41.00
G060007B
Figure 208. Station Diagram Model 500N
Page 210
Revision 23 060000
MAINTENANCE MANUAL
NOTE 2 CL
NOTE 3
0 20 40 60 80 120 140 160 180 200 220 240 260 280 300 320 340
STA
STA 100.00
15.00
WL
83.00
WL
14.00
WL
0.00
MID
FORWARD JACK POINT AFT STA
JACK POINT JACK POINT 338.36
P.STA STA STA STA STA
18.76 96.90 124.00 168.66 303.30
30 IN.
STA
78.50
P.STA P.STA
STA
0.00 30.00
0.00
(NOTE 1)
NOTES:
1. STA. 0.00, 15 INCHES (381 MM) FORWARD OF NOSE OF AIRCRAFT.
2. THIS DIMENSION 15 INCHES (381 MM) AFT OF NOSE OF AIRCRAFT.
3. THESE DIMENSIONS IN INCHES.
6G06004BA
Figure 209. Fuselage Station Diagram Model 600N
Page 211
060000 Revision 36
MAINTENANCE MANUAL
L137, R137
L153, R153
L167, R167
L166, R166
L158, R158
G060008
Item No. Name Permits Access To Qty. Type

L137 Plug Left forward upper longeron 1 Button Plug
R137 Plug Right forward upper longeron 1 Button Plug
L153 Plug Left upper longeron 1 Button Plug
R153 Plug Right upper longeron 1 Button Plug
L158 Plug Left lower longeron 1 Button Plug
R158 Plug Right lower longeron 1 Button Plug
L166 Plug Left lower attach fitting 1 Button Plug
R166 Plug Right lower attach fitting 1 Button Plug
L167 Plug Left upper attach fitting 1 Button Plug
R167 Plug Right upper attach fitting 1 Button Plug
Figure 210. Aft Empenage Access Plugs Model 600N
Page 212
Revision 34 060000
MAINTENANCE MANUAL
Chapter
07
Lifting and Jacking
MAINTENANCE MANUAL
TABLE OF CONTENTS
070000 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Component Weights for Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Approximate Maximum Hoisting Weights of Components
369D/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Helicopter Sling Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Helicopter Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Helicopter Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Helicopter Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Helicopter Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Hoisting and Jacking Helicopter (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . 204
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Section
070000
Lifting and Jacking
MAINTENANCE MANUAL
LIFTING AND JACKING

1. Component Weights for Hoisting Table 203. Approximate Maximum Hoisting
Weights of Components 500N
(Ref. Table 201 thru Table 204) The maximum
weights for large components that may require Wgt
hoisting are listed. Item Lb/kg
Use hoist with minimum 3500 Tailboom (w/o empennage, thruster) 35/16
CAUTION pound (1589 kg) capacity when
Main rotor hub 92/42
hoisting complete helicopter. Use hoisting
equipment with minimum 20% overrate to Main transmission (wet) (369D25100) 105/48
hoist heavier components of helicopter (Ref. Main transmission (wet) (369F5100) 140/64
Table 201 thru Table 204 for approximate
weights). Engine (builtup) 207/94
Table 201. Approximate Maximum Hoisting Helicopter (less main rotor hub, 1314/597
Weights of Components 369D/E swashplate, scissors and rotor blades)
Wgt Helicopter (complete) 1542/700

Item Lb/kg
Table 204. Approximate Maximum Hoisting
Tailboom 18/8
Weights of Components 600N
Main rotor hub 85/39
Wgt
Main transmission (wet) (369D25100) 105/48 Item Lb/kg
Main transmission (wet) (369F5100) 140/64
Tailboom (w/o empennage, thruster) 55/25
Engine (builtup) C20B 192/87
Main rotor hub (with dampers, pins) 107/49
Engine (builtup) C20R/2 207/94
Main transmission (wet) 140/64
Helicopter (less main rotor hub, 1153/523
swashplate, scissors and rotor blades) Engine (builtup) C47 292/133
Helicopter (complete) 1361/618 Helicopter (less main rotor hub, 1830/830
swashplate, scissors and rotor blades)
Table 202. Approximate Maximum Hoisting Helicopter (complete) 2100/953
Weights of Components 369FF
2. Helicopter Hoisting
Wgt
Item Lb/kg (Ref. Figure 201)
Tailboom 23/10
Special Tools
Main rotor hub 92/42 (Ref. Section 910000)
Item Nomenclature
Main transmission (wet) (369D25100) 105/48 ST201 Hoisting adapter
Main transmission (wet) (369F5100) 140/64 N/A Cable or Rope
Engine (builtup) 271/123
(1). Remove dome fairing (N/A 600N) from
Helicopter (less main rotor hub, 1369/622 main rotor hub and install hoisting
swashplate, scissors and rotor blades) adapter (ST201) on hub so that hoisting
eyebolts fit into slots on hoisting
Helicopter (complete) 1589/721 adapter.
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070000 Revision 23
MAINTENANCE MANUAL
(2). Install quick release pins. (7). Secure tail rotor hub to Sta. 284
bellcrank with strap or rope (369D/E/
(3). Attach cable from overhead hoist to FF only).
adapter eye.
(8). Position one person to support tail of
(4). Secure a line to tailboom. Have assis- helicopter.
tant hold line to keep helicopter from
swinging. (9). Position one person to accomplish
hookup to recovery helicopter.
(5). Hoist slowly and smoothly to maintain (10). Position one person in view of recovery
steady lifting force. helicopter to act as ground guide during
hookup.
3. Helicopter Sling Lifting
B. Helicopter Lifting
Follow below procedures for sling lifting the
helicopter. Tail of helicopter may come
WARNING down sharply if helicopter is
lifted abruptly.
Special Tools
(Ref. Section 910000) Avoid dragging helicopter dur-
Item Nomenclature
CAUTION ing lift before ground clearance
ST201 Hoisting adapter is obtained. Dragging helicopter may cause
extensive damage.
(1). Carefully lift helicopter. Ensure that
Slinglift helicopter only when
CAUTION other means of recovery are not person at tail of helicopter is familiar
with above warning.
available. Ensure recovery helicopter has
adequate capabilities, performance and fuel (2). Transport recovery crew and removed
to accomplish slinglift recovery. Ensure re- equipment to landing site before
covery crew has experience level to assure recovery helicopter with lifted helicop-
optimum performance at assigned positions. ter arrives.
Do not attempt lifting or lowering during
adverse wind or weather conditions. C. Helicopter Landing
A. Helicopter Preparations (1). Indicate wind direction with smoke

cannister.
Prepare helicopter to be lifted before attempt- (2). Ground guide recovery helicopter to
ing lift to avoid damage or loss of equipment hover into wind before lowering begins.
during flight.
Do not attempt lowering if heli-
(1). Remove dome fairing from main rotor CAUTION copter is spinning.
hub (N/A 600N).
(3). Lower helicopter.
(2). Remove main rotor blades (Ref. Sec.
621000). (4). Restrain and support tail of helicopter
as it contacts ground.
(3). Replace and secure blade damper bolts
Ground guide must signal re-
and attaching pins. CAUTION covery helicopter to move to one
(4). Tape elastomeric damper to pitch side before dropping sling or helicopter win-
housing. dow damage may occur.
(5). Signal recovery helicopter to drop sling.
(5). Install hoisting adapter (ST201).
(6). Remove sling and hoist adapter.
(6). Attach lifting straps or swivelequipped
cable slings that clear lead by 10 feet (7). Inspect recovered helicopter to deter-
(3.048 M) to hoisting adapter. mine condition.
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MAINTENANCE MANUAL
(8). Inspect main rotor blades prior to (1). Install jack fittings (ST202) in fuselage
installation for damage caused during jacking points. Secure jack fittings with
removal and transportation (Ref. Sec. locking pins located in fuel cell access
621000). doors.
4. Helicopter Jacking
NOTE: When jacking the 600N helicopter, only
(Ref. Figure 201) Provisions for jacking use the forward and aft jacking points.
helicopter are provided by two (369D/E/FF
500N) or four (600N) forward (side) jacking
point fittings and an aft jacking pad. The aft (2). Place suitable jacks (ST203 or ST204)
jack pad locations differ for the 369D/E/FF and under jack fittings and AFT jacking
the 500/600N helicopters. pad.
Special Tools
(Ref. Section 910000) NOTE: If helicopter is jacked from one side
Item Nomenclature only, in next step, a cushioned saddletype
support should be placed under tailboom at
ST202 Jack fittings
aft jacking pad location for extra stability.
ST203 Hydraulic jack: 15 ton (9004500 kg)
ST204 Hydraulic jack: 80 inch (203 cm) leg
(3). Raise helicopter to desired height.
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HUB FAIRING
SUPPORT
HOISTING EYEBOLTS
(3 PLACES)
HOISTING QUICK RELEASE PINS

ADAPTER (3 PLACES)
HOISTING
NOTE: HUB SUPPORT

REMOVED FOR CLARITY.
G0700011
Figure 201. Hoisting and Jacking Helicopter (Sheet 1 of 3)
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MAINTENANCE MANUAL
AFT JACKING PAD

(STA 197.2) (369D/E/FF)
LOCKPIN
AFT JACKING PAD

(STA 275.4) (500N)
JACK FITTING
JACKING
G0700012A
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070000 Revision 23
MAINTENANCE MANUAL
NOTE
HOISTING
ADAPTER
NOTE
NOTE
HOISTING
RELEASE PIN
(3 PLACES)
LOCKPIN
HOISTING EYEBOLT
(3 PLACES)
JACK FITTING
HOISTING
VIEW ROTATED
AFT JACKING PAD

(STA 303.3) (600N)
JACKING
NOTE: USE APPROPRIATE JACKING POINT 6G07005

ACCORDING TO C/G OF HELICOPTER.
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MAINTENANCE MANUAL
Chapter
08
Leveling/Weight and
Balance
MAINTENANCE MANUAL
TABLE OF CONTENTS
080000 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Helicopter Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Leveling Helicopter (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
081000 Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General Weight and Balance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Approved Center of Gravity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Helicopter Weighing Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Preparation for Weighing Electronic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Helicopter Weighing Electronic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Preparation for Weighing Mechanical Scales Method
(369D/E/FF 500N Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
E. Weighing Procedures Mechanical Scales Method
(369D/E/FF 500N Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F. Longitudinal CG Determination for Unadjusted Net Weight
(369D/E/FF 500N Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
G. Lateral CG Determination for Unadjusted Net Weight . . . . . . . . . . . . . . . . . . . . . . 205
H. Basic Weight and CG Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 201. Balance Diagram Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Balance Diagram Model 369E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Balance Diagram Model 369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 204. Balance Diagram Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 205. Balance Diagram Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 206. Weight and Balance Report Form (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 212
Figure 207. Surplus and Missing Items Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 208. Basic Weight and Balance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 209. Example 1 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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Section
080000
Leveling
MAINTENANCE MANUAL
LEVELING
1. Helicopter Leveling (1). Suspend plumb line from bracket on
right side of controls tunnel at Sta.
92.64, BL+ 6.20.
(Ref. Figure 201) Leveling is accomplished by
positioning helicopter to align a plumb bob (2). Adjust plumb line swing to leveling
with register marks on the target plate on target plate on floor of passenger/cargo
cargo compartment floor. compartment.
(3). With weight of helicopter supported by
Special Tools load cells of electronic weighing kit or
(Ref. Section 910000) jacks (ST203), as applicable, adjust
Item Nomenclature appropriate jack until plumb line is
centered (Ref. Sec. 070000, Helicop-
N/A Plumb bob (commercially available) ter Jacking).
N/A Twine
(a). Adjust side jacks to level helicopter
N/A Electronic weighing kit laterally.
ST202 Jack fittings (b). Adjust tailboom jack to level helicop-
ST203 Hydraulic jack: 15 ton (9004500 kg) ter longitudinally.
(c). Recheck lateral and longitudinal
levels until plumb bob exactly aligns
NOTE: Access to plumb line support bracket with marks on target plate.
and target plate on floor of passenger/cargo
compartment requires removal of trim on (4). After leveling helicopter, remove plumb
right side of controls tunnel, and floor carpet bob, reinstall trim and carpet, and close
in aft compartment (Ref. Chap. 25). compartment door.
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AFT JACKING PAD

(STA 275.4) (500N)
RIGHT EDGE OF
AFT JACKING PAD PLUMB LINE CONTROL TUNNEL
(STA 197.2) (369D/E/FF) SUPPORT CLIP
LOCKPIN
PLUMB LINE
JACK FITTING
TARGET PLATE
LEVELING
JACKING
G080001B
Figure 201. Leveling Helicopter (Sheet 1 of 2)
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MAINTENANCE MANUAL
PLUMB BOB SUPPORT

AFT JACKING POINT
JACKING
PLUMB LINE
TARGET
PLATE
LOCKPIN
LEVELING
JACK FITTING
JACKING
(FORE AND MID POINTS ARE TYPICAL)
6G08041A
Figure 201. Leveling Helicopter (Sheet 2 of 2)
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MAINTENANCE MANUAL
Section
081000
Weight and Balance
MAINTENANCE MANUAL
WEIGHT AND BALANCE

1. General Weight and Balance Information NOTE: Weight and balance information for op-
tional equipment is found in the Initial In-
(1). Removal or addition of fuel or equip- stallation section for the optional equip-
ment results in changes to weight and ment.
balance of a helicopter, and the permis-
sible useful load is affected accordingly. Wt
These changes must be investigated to Parameter lb/kg
eliminate possible adverse effects on
the helicopters flight characteristics. Certified Gross Weight (369D/E) 3000/1362
Certified Gross Weight (369FF) 3100/1407
(2). Basic weight and corresponding center
of gravity is determined by weighing Certified Gross Weight (500N) 3350/1521
the helicopter without crew and Certified Gross Weight (600N) 4100/1860
payload; however, basic weight does
include trapped and unusable fuel, full Cargo Deck Capacity 1300/590
operating fluids, lubricants, etc., and (369D/E/FF 500N)
installed equipment. Cargo Deck Capacity (600N) 1350/613
Cargo Deck Capacity not to exceed 115 pounds per
(3). 369D/E/FF 500N The longitudinal
square foot.
reference datum is located 100 inches
(254 cm) forward of the main rotor Certified Gross Weights are for weightonskids.
centerline. The lateral reference datum
is located along the longitudinal A. Approved Center of Gravity Limits
centerline of the helicopter. The vertical
reference datum is located at a point (Ref. PFM)
100 inches (254 cm) below the center of
the main rotor blades. B. Terminology
(4). 600N The Weight and Balance Following are terms with definitions, used
longitudinal reference datum is located when determining helicopter weight and
100 inches (254 cm) forward of the balance:
main rotor centerline or 15 inches (38.1 (1). Arm: The distance in inches from the
cm) aft of the aircraft nose. The Weight longitudinal (longitudinal arm) and
and Balance (longitudinal) Reference lateral (lateral arm) reference datum of
Datum is different from the Fuselage/ a part to the center of gravity (CG) of
Engineering Reference Datum (Ref. the part.
Section 060000). The lateral refer-
ence datum is located along the longitu- NOTE: When viewing helicopter from rear,
dinal centerline of the helicopter. The items to left of lateral reference datum (cen-
vertical reference datum is located at a ter line of helicopter) will be expressed as
point 83 inches (210.8 cm) below the having negative () lateral arm, and those
center of the main rotor blades. items to right of reference datum, a positive
(+) lateral arm.
(5). Refer to the following for balance
diagrams (2). Center of gravity (CG): A point on a
Figure 201 for Model 369D part where the part will be perfectly
Figure 202 for Model 369E balanced. Center of gravity is measured
Figure 203 for Model 369FF in inches from a known reference. It
Figure 204 for Model 500N can be determined using the following
Figure 205 for Model 600N. formula:
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081000 Revision 39
MAINTENANCE MANUAL
Moment (inlb) CAUTION

CG(in) =
Weight (lb)
D The controls access panel (aft side of Sta.
78.5 bulkhead) and the fuel cell access
(3). Moment: Product of weight of a part panels must be installed before jacking
and its arm, either longitudinal or helicopter.
lateral, and is expressed in inch D 369D/E/FF 500N: There are two meth-
pounds (inlb). ods approved for weighing the helicopter.
Longitudinal moment = weight x The preferred method is by using elec-
longitudinal arm; tronic weighing equipment. If equipment
Lateral moment = weight x lateral arm. for electronic weighing is unavailable, the
second approved method, mechanical
scales, may be used.
(4). Reaction point: A fixed point on helicop- D 600N: There is one method approved for
ter where weight of helicopter counter- weighing the helicopter. The method is by
acts on a weighing device. The main using electronic weighing equipment.
reaction points are;
A. Helicopter Weighing Preparation
(a). ALL: Long. Sta. 96.9. The following items are required and should be
readily available prior to preparing and
weighing the helicopter, using the electronic
(b). 369D/E/FF 500N: Lat. Sta. 25.6. weighing method.
Special Tools
(c). 600N: Lat. Sta. 26.0. (Ref. Section 910000)
Item Nomenclature
ST202 Jack fittings
(d). 369D/E/FF: Tail reaction point is at
Long. Sta. 197.2, Lat. Sta. 0.0.
NOTE:
(e). 500N: Tail reaction point is at Long. D Weigh helicopter without fuel if possible.
Sta. 275.4, Lat. Sta. 0.0. D 369D/E/FF 500N: If fuel is drained from
low point in cell, 1.4 pounds (0.64 kg) of
trapped fuel at 93.5 inch (237.5 cm) arm
(f). 600N: Tail reaction point is at Long. will remain. If fuel is pumped out using
Sta. 303.3, Lat. Sta. 0.0. start pump, 3.7 pounds (1.68 kg) of
trapped (unusable) fuel at 93.5 inch
(237.5 cm) arm will remain.
2. Helicopter Weighing D 600N: If fuel is drained from low point in
cell, 1.6 pounds (0.73 kg) of trapped (un-
usable) fuel at 93.5 inch (237.5 cm) arm
will remain. If fuel is pumped out using
Forms start pump, 9.5 pounds (4.31 kg) of
trapped (unusable) fuel at 93.5 inch
Form Figure (237.5 cm) arm will remain.
Nomenclature No. No.
(1). If defueling is not possible, ensure that
Weight and Balance Report 765B 206 fuel cell is full.
Surplus and Missing Items 1702 207 (a). Fluid weights at 70 ambient are:
Basic Weight and Balance 885 208 Fuel (Jet A)
Record 6.75 Lb (3.06 kg) per U.S. gallon
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Fuel (JP4) B. Preparation for Weighing Electronic

6.50 Lb (2.95 kg) per U.S. gallon Method
Fuel (JP5) Special Tools

6.80 Lb (3.09 kg) per U.S. gallon (Ref. Section 910000)
Item Nomenclature
Fuel (JP8)
6.75 Lb (3.06 kg) per U.S. gallon N/A Electronic weighing kit/Platform Scales
N/A Rollaway table (with weighing platform)
PRC Fuel (No 3) N/A Plumb Bob
6.75 Lb (3.06 kg) per U.S. gallon ST203 Hydraulic jack: 15 ton (9004500 kg)
Lubricating Oil
7.70 Lb (3.50 kg) per U.S. gallon
(1). Position hydraulic jack (ST203) under
(2). Defuel helicopter (Ref. Sec. 120000). each of main jacking points at Sta. 96.9,
left and right sides of helicopter.
(3). Select weighing area that is enclosed
and draftfree, with hardsurfaced (2). Position third hydraulic jack (ST203 or
floor. ST204), on rollaway table if needed,
and attached load cell at aft jacking
point of helicopter.
(4). Ensure that helicopter and weighing
area is cleared of all tools and debris. (3). Attach electronic weighing kit load cell
to each jack, and to weighing kit control
(5). 369D/E/FF 500N: Verify that five unit.
main rotor blades are uniformly spaced
(72 degrees apart). (4). Turn electronic weighing kit power ON
600N: Verify that six main rotor blades and allow warm up time as specified in
are uniformly spaced (60 degrees electronic weighing kit operation
apart). manual.
(6). Check lubricant level at engine oil tank, (5). Calibrate and zeroin each load cell
main rotor gear box and tail rotor or fan prior to applying aircraft load (Ref.
gearbox sight gages. Add lubricant as Electronic Weighing Kit operation
necessary where less than full indica- manual).
tion is noted (Ref. Sec. 120000).
On the 600N helicopter, never
CAUTION exceed aft (tailboom) jack load of
(7). Record weight, arm and moment of
surplus equipment on board helicopter 500 Lbs (227 kg).
at time of weighing, which will not be
part of basic helicopter weight (Ref. (6). Exercise load cells by jacking all three
Figure 206). jacks simultaneously until load is
supported by load cells at all jack point
stations. Do not check helicopter level
(8). Record weight, arm and moment of at this time.
missing equipment, to be installed after
weighing and prior to flight, that will (7). Lower helicopter to floor so that no load
become part of basic helicopter weight is supported by load cells.
(Ref. Figure 206).
(8). Repeat above steps (exercise load cells
(9). Install two fuselage jack fittings and lower helicopter) twice.
(ST202) for main weighing points at
Longitudinal Sta. 96.9 and Lateral Sta. (9). Recheck calibration and zero of each
25.6. Secure fittings with pip pins. load cell.
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081000 Revision 27
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C. Helicopter Weighing Electronic Method (Ref. Figure 209, example 1(b)). This
reading represents calibration correc-
When preparations have been made (Ref. tion for each load cell. Depending on
Helicopter Weighing Preparation and Prepara- sign shown on control unit (+ or ),
tion for Weighing Electronic Method), weigh reading will have to be added to or
helicopter as follows: subtracted from reading in step (3).
above to obtain corrected weight for
Special Tools each cell (Ref. Figure 209, example
(Ref. Section 910000) 1(c)).
Item Nomenclature
(6). Add corrected readings for all three
N/A Spirit level cells to determine total unadjusted net
N/A Plumb Bob weight of helicopter (Ref. Figure 209,
ST203 Hydraulic jack: 15 ton (9004500 kg) example 1(c).
D. Preparation for Weighing Mechanical
ST205 Inclinometer Scales Method (369D/E/FF 500N Only)
When preparing to weigh helicopter using
(1). Operate three hydraulic jacks (ST203 mechanical scales, complete preliminary
and/or ST204) simultaneously until procedure (Ref. Helicopter Weighing Prepara-
entire load is supported by load cells. tion), then perform the following:
NOTE: If conditions permit, helicopter may be
leveled using plumb bob instead of spirit Special Tools
level (Ref. Sec. 080000). (Ref. Section 910000)
Item Nomenclature
(2). After landing gear skids are clear of
floor, level helicopter as follows: N/A Rollaway table (with weighing platform)
N/A Beam platform scales (two), 1000 lb. (450
(a). Remove main rotor hub fairing (Ref. kg) capacity with current calibration
Sec. 622000) (N/A 600N). N/A Platform scale, 300 lb. (135 kg) capacity
with current calibration
(b). Check lateral level by placing spirit
level on main rotor mast, with axis of ST202 Jack fittings
spirit level 90 degrees to longitudinal ST203 Hydraulic jack: 15 ton (9004500 kg)
axis of helicopter. Adjust left or right ST204 Hydraulic jack: 80 inch (203 cm) leg
jack at main jack points, as required,
to center bubble in spirit level.
(1). Check 1,000 lb. (450 kg) capacity scales
(c). Place protractor or inclinometer for zero.
(ST205) on main rotor mast so that
its axis is parallel to longitudinal axis (2). Place 300 lb. (135 kg) capacity scale on
of helicopter. Adjust jack at aft rollaway table with weighing platform,
jacking point until protractor or and check zero on scale.
inclinometer shows 3 degrees forward (3). Hoist helicopter so that main landing
tilt. gear skids are sufficiently clear of floor
(d). Reinstall hub fairing (N/A 600N). to enable 1,000 lb. (450 kg) capacity
beam platform scales to be rolled under
(3). Record reading shown on weighing kit main skids on left and right sides.
control unit for each load cell (Ref.
Figure 209, example 1(a)). (4). Roll 1,000 lb. (450 kg) capacity beam
platform scales under main skids and
(4). Lower helicopter to floor by bleeding off position so main jack fittings (ST202) at
jacks, and clear load cells. Sta. 96.9 are on centerline of scale.
(5). Record reading on control unit for each (5). Place jack (ST203) on 300 lb. (135 kg)
load cell under NO LOAD condition capacity platform scale (67). Position
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Revision 23 081000
MAINTENANCE MANUAL
rollaway table so that jack and 300 weight at each reaction point (Ref.
pound capacity scale are directly below Figure 209, example 1(b)).
AFT jacking point.
(9). Subtract total tare weight for the three
(6). Lower helicopter so its weight is reaction points obtained in step h above
supported by scales. from weight recorded in step c above to
obtain total unadjusted net weight of
(7). Place jack on each 1,000 lb. (450 kg) helicopter (Ref. Figure 209, example
capacity platform scale, inboard of main 1(c)).
skids and directly below main jacking
points at Sta. 96.9. F. Longitudinal CG Determination for
Unadjusted Net Weight (369D/E/FF 500N
E. Weighing Procedures Mechanical Only)
Scales Method (369D/E/FF 500N Only)
(1). Multiply net weight obtained at each
Once preparations have been completed (Ref. jacking point by its longitudinal arm, to
Helicopter Weighing Preparation and Prepara- obtain a moment (Ref. Figure 209,
tion for Weighing Mechanical Scales Meth- example 1(d)).
od), weigh helicopter as follows: (2). Add three moments determined in step
(1). Operate jacks (ST203 and/or ST204) (1). to calculate total moment (Ref.
simultaneously until helicopter is Figure 209, example 1(e)).
supported only by jacks at right and left (3). Divide total moment obtained in step
Sta. 96.9 and AFT reaction points. (2). by total unadjusted net weight, to
determine longitudinal CG (Ref.
NOTE: If conditions permit, helicopter may be Figure 209, example 1(f)).
leveled using plumb bob instead of spirit
level (Ref. Sec. 080000). G. Lateral CG Determination for Unadjusted
Net Weight
(2). With main skids clear of 1,000 lb. (450
kg) capacity platform scales, level NOTE: Lateral CG is not critical with normal
helicopter (Ref. Helicopter Weighting internal loading. Certain optional equip-
Electronic Method). ment, such as an external cargo hook, may
induce lateral CG outside lateral CG limits,
(3). Record weight shown on scale at each if weight and CG control is not provided.
reaction point (Ref. Figure 209, exam- However, the Initial Installation section for
ple 1(a)). each optional equipment installation pro-
vides complete instructions on lateral CG
(4). Simultaneously bleed off hydraulic control, to ensure operation within ap-
jacks until helicopter skids contact proved limits.
1,000 lb. (450 kg) platform scales, and
total weight of helicopter is supported (1). Multiply net weight for each jacking
by scales and AFT jack point. point by its lateral reaction point
(369D/E/FF 500N: left main, 25.6;
(5). Remove jacks from 1,000 lb. (450 kg) right main, +25.6; and aft, zero)
capacity platform scales. (600N: left main, 26.0; right main,
+26.0; and aft, zero) to obtain moment
(6). Hoist helicopter until scales at right for each jacking point (Ref. Figure 209,
and left sides and jack at aft reaction example 1(g)).
point can be rolled clear of helicopter
(Ref. Sec. 070000). (2). Add three moments determined in step
(1). above to calculate total moment
(7). Lower helicopter to floor. (Ref. Figure 209, example 1(h)).
(8). Weigh each jack on same scale jack (3). Divide total moment by total unad-
occupied during helicopter weighing to justed net weight to determine lateral
get the tare weight. Record the tare CG (Ref. Figure 209, example 1(i)).
Page 205
081000 Revision 23
MAINTENANCE MANUAL
H. Basic Weight and CG Determination moment of helicopter determined in

step (1). above.
Using unadjusted net weight and longitudinal (3). Enter total basic weight, CG and
moment, determine basic weight and CG of moment in Basic Weight and Balance
helicopter (Ref. Figure 209, example 1). Record (Ref. Figure 208).
NOTE: Any changes that will affect basic
(1). Add total weight and moment of weight and CG of helicopter must be re-
missing equipment to unadjusted net corded on Basic Weight and Balance Record
weight and moment of helicopter. (Ref. Figure 208), and revised basic weight
and CG of helicopter must be calculated
(2). Subtract total weight and moment of (Ref. PFM for preflight weight and balance
surplus equipment from weight and requirements).
Page 206
Revision 23 081000
MAINTENANCE MANUAL
STA. STA.
78.5 ROTOR CL 124.0
CG OF COPILOT/PASSENGER STA. CARGO COMPARTMENT
STA. 100.0
28.0
STA.
174.0
+13 +12.1
REFERENCE DATUM
13 12.1
TWOPLACE COCKPIT
CG OF PILOT STA. (OPTIONAL)
STA.
73.3 105.0
STA. STA.
78.5 ROTOR CL 124.0
CG OF RIGHT SIDE STA.
FWD PASSENGER CARGO COMPARTMENT
100.0
STA.
28.0
STA.
174.0
+18.1
+12.1
+2.6 REFERENCE DATUM
12.1
13.0
CG OF AFT PASSENGERS
CG OF FWD PASSENGER
CG OF PILOT THREEPLACE COCKPIT
STA.
28.0 STA. 71.50 STA. STA. (STANDARD)
73.5 105.0
PERMISSIBLE CG LIMITS
20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
SLING POINT OIL TANK (RH SIDE)
LEVELING PLUMB FIREWALL

STA. 92.6
JIG POINT
3 AFT JACKING POINT
STA. 197.2 BL 0.00
STA. 174.0 STA.
BDH 284.0
ENGINE SECTION
REFERENCE FUEL CELL COMPARTMENT
BATTERY STA. STA.
DATUM
78.5 124.0
JIG POINT
MAIN JACKING POINT
STA. 96.9 BL 25.6
G081001
Figure 201. Balance Diagram Model 369D
Page 207
081000 Revision 23
MAINTENANCE MANUAL
STA. STA.
78.5 ROTOR CL 124.0
CG OF COPILOT/PASSENGER STA.
CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM
12.2
13.0
TWOPLACE COCKPIT
(WITH DUAL CONTROLS)
CG OF PILOT
STA. STA.
73.3 105.0
STA. STA.
78.5 124.0
CG OF RIGHT SIDE ROTOR CL
FWD PASSENGER STA. CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM
12.2
13.0 THREEPLACE COCKPIT
(WITH SINGLE CONTROLS)
CG OF FWD PASSENGER
CG OF AFT PASSENGERS
CG OF PILOT
STA. STA.
STA. 71.5 73.5 105.0
STA.
15.00 STA.
STA. 99.0 107.4
20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
SLING POINT OIL TANK (RH SIDE)
LEVELING PLUMB
STA. 92.6
FIREWALL
3 JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
STA. 174.0 STA.
BDH 284.0
ENGINE SECTION
REFERENCE STA. STA. FUEL CELL JIG POINT
BATTERY 78.5 124.0 COMPARTMENT
DATUM MAIN JACKING POINT
STA. 96.9 BL 25.6
G081002
Figure 202. Balance Diagram Model 369E
Page 208
Revision 23 081000
MAINTENANCE MANUAL
STA. STA.
78.5 ROTOR CL 124.0
CG OF COPILOT/PASSENGER STA.
CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM
12.2
13.0
TWOPLACE COCKPIT
(WITH DUAL CONTROLS)
CG OF PILOT
STA. STA.
73.3 105.0
STA. STA.
CG OF RIGHT SIDE 78.5 124.0
FWD PASSENGER ROTOR CL
STA. CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM

12.2
13.0 THREEPLACE COCKPIT
(WITH SINGLE CONTROLS)
CG OF FWD PASSENGER CG OF AFT PASSENGERS
CG OF PILOT
STA. 71.5 STA. STA.
73.5 105.0
STA.
STA.
107.4
15.00 STA. 99.0
20 40 60 80
100 120 140 160 OIL TANK (RH SIDE)
SLING POINT
180 200 220 240
260 280 300
LEVELING PLUMB FIREWALL

STA. 92.6
3 JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
STA. 174.0 STA.
BDH 284.0
ENGINE SECTION
REFERENCE STA. STA. FUEL CELL
BATTERY
DATUM 78.5 124.0 COMPARTMENT JIG POINT
MAIN JACKING POINT
STA. 96.9 BL 25.6
G081003
Figure 203. Balance Diagram Model 369FF
Page 209
081000 Revision 23
MAINTENANCE MANUAL
ROTOR
STA CL STA
78.5 124.0
CARGO COMPARTMENT
CG OF COPILOT/ STA
PASSENGER 100.0
STA STA
15.0 168.8
+ 15.5 + 12.2
0.0 REFERENCE
DATUM
13.0 12.2
TWOPLACE COCKPIT
CG OF PILOT WITH DUAL CONTROLS
STA STA
73.5 105.0
ROTOR
CL
STA STA
78.5 124.0
STA CARGO COMPARTMENT
CG OF COPILOT/ 100.0
PASSENGER
STA STA
15.0 168.8
+ 15.5 + 12.2
+ 0.8 REFERENCE
CG OF CENTER 0.0 DATUM
PASSENGER 12.2
13.0
CG OF PILOT THREEPLACE COCKPIT

STA WITH SINGLE CONTROLS
73.5 STA
STA STA 105.0
15.0 STA STA 71.5
28.0 100.0
0 20 40 60
80 100 120 140 3
160 180 200 220
240 260 290 300
320LEVELING PLUMB OIL TANK RH SIDE
STA 92.6
FIREWALL
REFERENCE DATUM
JIG POINT
ENGINE SECTION AFT JACKING POINT
STA 275.4
FUEL CELL
COMPARTMENT
STA STA
78.5 124.0
JIG POINT
FWD JACKING POINT
STA 96.9
G081007
Figure 204. Balance Diagram Model 500N
Page 210
Revision 23 081000
MAINTENANCE MANUAL
CG OF PILOT OR
COPILOT/PASSENGER 7-PLACE SEATING,
TWO-PLACE COCKPIT WITH DUAL CONTROLS,
AFT-FACING MID-CABIN SEAT
+ 15.0 + 12.2
MID SEAT
0.00 0.00 REFERENCE DATUM
13.0 12.2
15.0
STA
STA
70.4
41.50
8-PLACE SEATING,
THREE-PLACE COCKPIT WITH SINGLE CONTROLS,
FWD-FACING MID-CABIN SEAT
MID SEAT
0.00 0.00 REFERENCE DATUM
STA STA STA

43.50 77.1 105.0
PASSENGER/CARGO
COMPARTMENT
THIS DIMENSION 15 INCHES

(381 MM) AFT OF NOSE OF STA THESE DIMENSIONS
AIRCRAFT 100 IN INCHES
0 20 40 60
80 120 140 160
180 200 220 240 3
260 280 300 320
LEVELING PLUMB
340
STA 81.54
BL 4.00
FIREWALL
ENGINE SECTION
FUEL CELL AFT JACKING

POINT STA 303.3
WEIGHT AND BALANCE
COMPARTMENT
REFERENCE DATUM
JIG POINT
MID JACKING POINT
STA 96.9
JIG POINT
FORWARD
JACKING POINT P.STA 18.76 OR
67.40 INCHES FROM DATUM 6G08007B
Figure 205. Balance Diagram Model 600N
Page 211
081000 Revision 36
MAINTENANCE MANUAL
WEIGHT AND BALANCE REPORT

MODEL ___________
WEIGHED BY CONFIGURATION
MODEL SERIAL NO. REGISTRATION NO. DATE
TARE OR NET LONGITU- LATERAL LONGITU- LATERAL

WEIGHING SCALE READING CALIBRATION WEIGHT DINAL ARM DINAL MOMENT
POINTS (LBS) CORRECTION (LBS) ARM (INCHES) MOMENT (INCHLBS)
(LBS) (INCHES) (INCHLBS)
LEFT MAIN 96.9 26.0
RIGHT MAIN 96.9 +26.0
TAIL 303.3 0.0
TOTAL UNADJUSTED NET WEIGHT
TOTAL WEIGHT OF SURPLUS EQUIPMENT (SEE TABLE 1)

TOTAL WEIGHT OF MISSING EQUIPMENT (SEE TABLE 1) +
TOTAL BASIC WEIGHT
FUEL/OIL ABOARD AT TIME OF WEIGHING:
EMPTY FULL
FUEL
ENGINE OIL
MAIN GEAR BOX
TAIL GEAR BOX
McDonnell Douglas
FORM 765B (REV 483) Page 1 of Helicopter Company
Figure 206. Weight and Balance Report Form (Sheet 1 of 2)
Page 212
Revision 23 081000
MAINTENANCE MANUAL
EXAMPLES OF FORWARD, AFT AND LATERAL LOADING
LONG. LONG.
WEIGHT
EXAMPLE 1, FORWARD (LBS)
ARM MOMENT
(IN.) (IN. LB.)
BASIC WEIGHT
PILOT 43.5
COPILOT 43.5
FULL FUEL QUANTITY
GROSS WEIGHT (CRITICAL FUEL) FWD C.G.
APPROVED FWD C.G. LIMIT FOR EXAMPLE 1 GROSS WEIGHT * INCHES.
LONG. LONG.
WEIGHT
EXAMPLE 2, AFT (LBS)
ARM MOMENT
(IN.) (IN. LB.)
BASIC WEIGHT
PILOT
GROSS WEIGHT (ZERO FUEL) AFT C.G.
APPROVED AFT C.G. LIMIT FOR EXAMPLE 2 GROSS WEIGHT * INCHES.
LATERAL LATERAL
WEIGHT
EXAMPLE 3, LATERAL (LBS)
ARM MOMENT
(IN.) (IN. LB.)
BASIC WEIGHT
PILOT
GROSS WEIGHT (ZERO FUEL) LATERAL C.G.
APPROVED LATERAL C.G. FOR EXAMPLE 3 GROSS WEIGHT * INCHES.
*SEE FLIGHT MANUAL, SECTION 6, FOR C.G. LIMITS AT GROSS WEIGHT
Figure 206. Weight and Balance Report Form (Sheet 2 of 2)
Page 213
081000 Revision 23
MAINTENANCE MANUAL
TABLE 1 SURPLUS AND MISSING EQUIPMENT

WEIGHT ARM INCHES MOMENT IN/LBS
EQUIPMENT ITEM LBS LONG LATR LONG LATR
SURPLUS EQUIPMENT TOTAL: ( 1.3 ) ( 96.9 ) ( ) ( 126 ) ( )
JACK PADS (2) 1.3 96.9 126
MISSING EQUIPMENT TOTAL: ( 15.9 ) ( 97.4 ) ( ) ( 1549 ) ( )
ONE QT. ENGINE OIL 2.1 133.4 280

UNUSABLE FUEL 12.0 93.0 1116
FLIGHT MANUAL 1.8 85.0 153
McDonnell Douglas
FORM 1702 (REV 483) Page of Helicopter Company
Figure 207. Surplus and Missing Items Report
Page 214
Revision 23 081000
BASIC WEIGHT AND BALANCE RECORD
( CONTINUOUS HISTORY OF CHANGES IN STRUCTURE OR EQUIPMENT AFFECTING WEIGHT AND BALANCE )
AIRCRAFT MODEL SERIAL NUMBER REGISTRATION NUMBER
PAGE OF
WEIGHT CHANGE RUNNING TOTAL

ITEM NO. ADDED (+) REMOVED () BASIC AIRCRAFT
DATE DESCRIPTION OF ARTICLE OR MODIFICATION
LONG MOMENT1 LONG MOMENT1 LONG MOMENT
WEIGHT ARM WEIGHT WEIGHT
IN OUT IN .LB. ARM IN .LB. ARM IN .LB.
BASIC WEIGHT DELIVERY 1510.0 109.0 164561
MAINTENANCE MANUAL
081000
Figure 208. Basic Weight and Balance Record
1 ENTER CONSTANT USED BELOW LINE
FORM 885 ( REV 2/82 ) MD HELICOPTERS INC
G081006A
Revision 23
Page 215
CSPHMI2
MAINTENANCE MANUAL
Determining total unadjusted net weight and longitudinal CG 369D/E/FF

(a) (b) (c) (d)
Tare or
Weighing Scale Calibration Net Arm
Points Reading (lbs) Correction (lbs) Weight (lbs) (inches) Moment (in.lb)
Left Main 648.9 1.5 647.4 96.9 62733
Right Main 618.9 + 0.5 619.4 96.9 60020
Tail 195.9 0 195.9 197.2 38631
Total Unadjusted Net Weight 1462.7 110.3 161384
(f) (e)
Determining total unadjusted net weight, longitudinal and lateral CG 500MD
(a) (b) (c) (d) (g)

Tare or
Scale Calibration Net Longitudinal Lateral Longitudinal Longitudinal
Weighing Reading Correction Weight Arm Arm Moment Moment
Points (lbs) (lbs) (lbs) (inches) (inches) (inchlb) (inchlb)
Left Main 1020.0 0.0 1020.0 96.9 25.6 98838 62733
Right Main 939.0 0.0 939.0 96.9 + 25.6 90989 60020
Tail 128.0 0.0 128.0 197.2 0.0 25242 0
Total Unadjusted Net Weight 2087.0 103.1 1.0 215069 2084
(f) (i) (e) (h)
Determining total unadjusted net weight, longitudinal and lateral CG 500N
(a) (b) (c) (d) (g)

Tare or
Scale Calibration Net Longitudinal Lateral Longitudinal Longitudinal
Points (lbs) (lbs) (lbs) (inches) (inches) (inchlb) (inchlb)
Left Main 759.0 0.0 759.0 96.9 25.6 73547.1 19430.4
Right Main 738.8 0.0 738.8 96.9 +25.6 71589.7 18913.2
Tail 136.8 0.0 136.8 275.4 0 3764.7 0
Total Unadjusted Net Weight 1634.6 111.8 .3 182811.5 5172
(f) (i) (e) (h)
Figure 209. Example 1 (Sheet 1 of 2)
Page 216
Revision 23 081000
MAINTENANCE MANUAL
Determining total unadjusted net weight, longitudinal and lateral CG 600N
(a) (b) (c) (d) (g)

Tare or
Scale Calibration Net Longitudinal Lateral Longitudinal Lateral
Points (lbs.) (lbs.) (lbs.) (inches) (inches) (inchlbs.) (inchlbs.)
Left Main 919.2 0.0 919.2 96.9 26.0 89070 23899
Right Main 885.4 0.0 885.4 96.9 +26.0 85795 23020
Tail 104.7 0.0 104.7 303.3 0 31756 0
Total Unadjusted Net Weight 1909.3 108.2 .5 206621 879
(f) (i) (e) (h)
Determining basic weight and the longitudinal and lateral CG 500MD

Weighing Scale Tare or Net Weight Arm Moment
Points Reading Calibration (lbs) (in.) (in.lb)
(lbs) Correction
(lbs)
Left Main 648.9 1.5 647.4 96.9 62733

Right Main 618.9 + 0.5 619.4 96.9 60020
Tail 195.9 0 195.9 197.2 38631
Total Unadjusted Net Weight 1462.7 110.3 161384
Total Weight of Missing Equipment (Ref. Figure 207) + 21.0 93.6 + 1966
Total Weight of Surplus Equipment (Ref. Figure 207) 1.3 96.9 126
Total Basic Weight 1482.4 110.1 163224
Determining basic weight and the longitudinal and lateral CG 600N

Tare or
Scale Calibration Longitudin Lateral Longitudin Lateral
Weighing Reading Correction Net Weight al Arm Arm al Moment Moment
Points (lbs.) (lbs.) (lbs.) (inches) (inches) (inchlbs.) (inchlbs.)
Left Main 919.2 0.0 919.2 96.9 26.0 89070 23899
Right Main 885.4 0.0 885.4 96.9 +26.0 85795 23020
Tail 104.7 0.0 104.7 303.3 0 31756 0
Total Unadjusted Net Weight 1909.3 108.2 .5 206621 879
Total Weight of Missing Equipment +15.9 97.4 0 1549 0
(Ref. Figure 207)
Total Weight of Surplus Equipment 1.3 96.9 0 126 0
(Ref. Figure 207)
Total Basic Weight 1923.9 108.1 .5 208044 879
Figure 209. Example 1 (Sheet 2 of 2)
Page 217
081000 Revision 23
MAINTENANCE MANUAL
Page 218
Revision 43 081000
MAINTENANCE MANUAL
Chapter
09
Towing
MAINTENANCE MANUAL
TABLE OF CONTENTS
090000 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Standard Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Special Ground Handling Wheels (FloatEquipped Helicopters,
369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Towing and Manual Moving (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . 201
3. Helicopter Manual Moving (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Helicopter Towing (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Towing Helicopter (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Towing Helicopter (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
090000
Towing
MAINTENANCE MANUAL
TOWING
1. Ground Handling Wheels Excessive leadlag load applied
CAUTION to the main rotor blades during
ground handling can result in damage to the
NOTE: At regular intervals, check wheel tire elastomeric damper buns and failure of the
pressure and repack wheel bearings (Ref. damper assembly. Operators and mainte-
Sec. 324000/324060). nance personnel should use extra caution to
avoid leadlag loads in excess of 35 lb. (16
kg) at the tip of the main rotor blades.
A. Standard Ground Handling Wheels
(1). Attach ground handling wheels (ST101
or ST104) as shown (Ref. Figure 201),
(Ref. Figure 201) Standard ground handling and hold tail up while lowering the
wheels, available as a special tool for helicop- wheels (raising helicopter) with
ters not equipped with floats, are used for detachable jack handle (ST102 or
moving helicopter by hand and for towing ST103).
helicopter. The wheels are manually lowered
with a detachable jack handle and are held in (2). Manually move helicopter on ground
the down position (helicopter raised on wheels) handling wheels by balancing at
by a mechanical lock. The wheels for the tailboom and pushing on rear fuselage
369D/E/FF 500N helicopters are equipped portion of airframe.
with tow bar attach fitting.
Except under extreme emergen-
CAUTION cy conditions, do not tow heli-
B. Special Ground Handling Wheels copter at speeds over 5 mph (8 KmH). Do not
(FloatEquipped Helicopters, 369D/E/FF allow front ends of skid tubes to drag on
500N) ground. Avoid sudden stops and starts, and
short turns which could cause helicopter to
turn over. Allow inside wheel to turn (not
Special ground handling wheels are available pivot) while helicopter is being turned. Safe
for towing helicopters equipped with utility or minimum turning radius is approximately
emergency floats (Ref. Sec. 324000). 20 ft. (6 M).
NOTE: If tow bar is not equipped to keep front

2. Helicopter Towing and Manual Moving end of skid tubes from dragging, have an as-
(369D/E/FF 500N) sistant balance helicopter at tailboom.
(3). Tow helicopter on ground handling

wheels by attaching suitable tow bar to
Special Tools tow bar fittings.
(Ref. Section 910000)
Item Nomenclature 3. Helicopter Manual Moving (600N)
ST101 Ground handling wheels
(Ref. Figure 202)
ST102 Handlejack assembly, ground handling
(straight)
Special Tools
ST103 Handlejack assembly, ground handling (Ref. Section 910000)
(offset) Item Nomenclature
ST104 Ground handling wheels (one side) ST101 Ground handling wheels
Page 201
090000 Revision 23
MAINTENANCE MANUAL
Excessive leadlag load applied ground handling wheel set, allowing the
CAUTION to the main rotor blades during helicopter to be moved by one person.
elastomeric damper buns and failure of the
Special Tools
damper assembly. Operators and mainte-
nance personnel should use extra caution to
Item Nomenclature
avoid leadlag loads in excess of 35 lb. (16
kg) at the tip of the main rotor blades. ST101 Ground handling wheels
ST105 Tow bar (600N)
(1). Ensure all stress panels are installed
on helicopter before jacking.
Excessive leadlag load applied
NOTE: CAUTION to the main rotor blades during
D The ground handling wheel set can be at- ground handling can result in damage to the
tached to the skids facing either direction elastomeric damper buns and failure of the
for ease of jacking. damper assembly. Operators and mainte-
D Ensure all four ground handling attach nance personnel should use extra caution to
points are engaged in ground handling avoid leadlag loads in excess of 35 lb. (16
wheel set. kg) at the tip of the main rotor blades.
(2). Attach ground handling wheels (ST101) (1). Ensure all stress panels are installed
and hold tail up while lowering the on helicopter before jacking.
wheels (raising helicopter).
(2). Raise helicopter with ground handling
(3). Manually move helicopter on ground wheel set (ST101).
handling wheels by balancing at
tailboom and pushing on rear fuselage (3). Position tow bar (ST105), with caster
portion of airframe. wheels, straddling front of skid tube
assembly.
CAUTION cy conditions, do not tow heli- (4). Attach nylon straps under skid tube
copter at speeds over 5 mph (8 KmH). Do not and ratchet skid tube into rubber cups
allow front ends of skid tubes to drag on on tow bar.
ground. Avoid sudden stops and starts, and
short turns which could cause helicopter to CAUTION cy conditions, do not tow heli-
turn over. Allow inside wheel to turn (not
copter at speeds over 5 mph (8 KmH). Do not
pivot) while helicopter is being turned. Safe
allow front ends of skid tubes to drag on
minimum turning radius is approximately
ground. Avoid sudden stops and starts, and
20 ft. (6 M).
short turns which could cause helicopter to
4. Helicopter Towing (600N) turn over. Allow inside wheel to turn (not
pivot) while helicopter is being turned. Safe
(Ref. Figure 202) The tow bar is equipped with minimum turning radius is approximately
caster wheels and is designed for use with the 20 ft. (6 M).
Page 202
Revision 23 090000
MAINTENANCE MANUAL
WARNING:
BE SURE LOCK SNAPS INTO
POSITION SHOWN BEFORE
LOCK RELEASING JACK HANDLE
TOW BAR FITTING
JACK HANDLE
WHEELS LOWERED AND LOCKED
(HELICOPTER RAISED)
HANDLE LOCK PIN
GROUND HANDLING WHEELS

AND JACK ASSEMBLY
SKID TUBE
(RIGHT SIDE SHOWN)
SKID FITTING
WHEELS RAISED (HELICOPTER

LOWERED)
G090001
Figure 201. Towing Helicopter (369D/E/FF 500N)
Page 203
090000 Revision 23
MAINTENANCE MANUAL
TOW BAR
TOW BAR
SKID TUBE AS-

SEMBLY
VIEW ROTATED
GROUND HANDLING
WHEEL SET
SKID TUBE
ASSEMBLY
GROUND HANDLING
ATTACH POINTS
VIEW ROTATED
6G09040
Figure 202. Towing Helicopter (600N)
Page 204
Revision 23 090000
MAINTENANCE MANUAL
Chapter
10
Parking and Mooring
MAINTENANCE MANUAL
TABLE OF CONTENTS
101000 Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Helicopter Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Parking and Mooring (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
102000 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Preservation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Flyable Storage (No Time Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Inspection Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Storage Up to 45 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Inspection During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Storage Up to 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Inspection During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
103000 Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Blades Storage Rack Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Rotor Blades Storage Rack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Main Rotor Blades Folding and Unfolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Helicopter Location for Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Rotor Blades Folddown Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Aft Main Rotor Blades Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Forward Main Rotor Blades Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Folding and Stowing Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . 204
E. Main Rotor Blades Unfolding Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F. Aft Main Rotor Blades Unfolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
G. Forward Main Rotor Blades Unfolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
H. Main Rotor Blades Storage Rack Removal and Storage . . . . . . . . . . . . . . . . . . . . . 206
4. Main Rotor Flight Controls Adjustment and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
101000
Parking and Mooring
MAINTENANCE MANUAL
PARKING AND MOORING

1. Helicopter Parking (c). Secure blade sock tiedown cord for
blade located above tailboom to
To park helicopter for short intervals, perform tailboom. Secure other blade sock
following steps (1). thru (4). For longer tiedown cords to fuselage jack fittings
duration parking, also perform steps (5). and (ST202).
(6).
(4). Secure sixbladed main rotor blades as
follows:
Special Tools
(Ref. Section 910000) When securing blade sock tie-
Item Nomenclature CAUTION down cords, take up slack but do
ST202 Jack fittings not apply bending loads on blades.
ST2002 Blade socks (a). Position blades so that three blades
ST2004 Air inlet fairing cover are on each side of helicopter (Ref.
ST2005 Engine exhaust cover Figure 201).
(b). Install blade socks (ST2002) on all
To prevent rotor damage from blades.
CAUTION blade flapping (droop stop (c). Secure blade sock tiedown cords to
pounding) as a result of air turbulence from fuselage jack fittings or cabin steps.
other aircraft landing, taking off or taxiing,
or sudden wind gusts, rotor blades should be (5). Install air inlet fairing cover (ST2004)
secured whenever helicopter is parked. on air inlet front fairing (Ref.
Figure 201).
(1). Locate helicopter slightly more than
blade clearance from nearby objects on (6). Install engine exhaust cover (ST2005)
most level ground available. on exhaust tailpipe (Ref. Figure 201).
(2). Apply friction to lock cyclic and collec- 2. Helicopter Mooring
tive sticks so that friction control knobs
are positioned as follows: neutral for Whenever severe storm conditions or wind
cyclic stick and full down for collective velocities higher than 40 knots are forecast,
stick. helicopter should be hangared or evacuated to
a safer area. If these precautions are not
NOTE: If not already accomplished, apply possible, moor helicopter as follows.
paint mark on edge of guide to locate neu-
tral position for future reference (Ref. Sec. Special Tools
671000). (Ref. Section 910000)
(3). Secure fivebladed main rotor blades as Item Nomenclature
follows: N/A Stakes or ground anchors (two)
N/A Cable or rope
When securing blade sock tie-
CAUTION down cords, take up slack but do
ST202 Jack fittings
not apply bending loads on blades. ST2001 Pitot tube cover
ST2004 Air inlet fairing cover
(a). Turn blades until one blade is ST2005 Engine exhaust cover
directly above tailboom (Ref.
Figure 201).
(1). Park helicopter (Ref. Helicopter
(b). Install blade socks (ST2002) on all Parking) or remove main rotor blades
blades. (Ref. Sec. 621000) and install air
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MAINTENANCE MANUAL
inlet fairing cover (ST2004) and engine (4). Apply friction to lock cyclic and collec-
exhaust (ST2005) covers. tive sticks (Ref. Helicopter Parking).
(5). Secure helicopter to ground by attach-
(2). Install pitot tube cover (ST2001). ing restraining lines (cable or rope)
between jack fittings (ST202) and
(3). Fill fuel tank (if possible) (Ref. Sec. stakes or ground anchors (Ref.
120000). Figure 201).
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MAINTENANCE MANUAL
G101001
Figure 201. Parking and Mooring (Sheet 1 of 2)
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101000 Revision 23
MAINTENANCE MANUAL
BLADE SOCK
(6 PLACES)
CABLE OR
MANILA ROPE
(6 PLACES)
MOORING ANCHOR
(4 PLACES)
ENGINE EXHAUST
COVER
ZIPPER
AIR INLET
FAIRING
COVER
PITOT TUBE
COVER DOOR
ACCESS
LATCH
PITOT TUBE TIE CORD

COVER INSTALLATION
FUEL CELL
ACCESS DOOR
LOCKPIN ENGINE AIR INLET

LOCKPIN
JACK FITTING STOWAGE FAIRING COVER
INSTALLATION
TO BLADE SOCK FUESELAGE
STRUCTURE
JACK FITTING
TO MOORING
ANCHOR
TO BLADE
SOCK
JACK FITTING INSTALLATION

(TYPICAL 2 PLACES)
f60039
Figure 201. Parking and Mooring (Sheet 2 of 2)
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Revision 23 101000
MAINTENANCE MANUAL
Section
102000
Storage
MAINTENANCE MANUAL
STORAGE
1. Preservation and Storage (e). Open movable air vents in each door
of cargo compartment. Position
A helicopter to be placed in storage or nonop- opening in each air vent downward.
erational status must have adequate inspec- Close all other vents.
tion, maintenance and preservation to avoid
unnecessary deterioration of airframe and (f). Install covers and equipment used to
components of equipment. Extent of preventive park and moor helicopter.
maintenance that is to be performed depends
(g). Install a static ground.
on anticipated time in storage. Following
paragraphs describe what should be performed C. Return to Service
in helicopter: for flyable storage; for up to 45
days in storage; and for up to 6 months in (1). Remove covers and equipment used to
storage. park and moor helicopter.
(2). Perform Daily PreFlight Check (Ref.
2. Flyable Storage (No Time Limit) appropriate PFM or RFM).
A. Inspection Before Storage 3. Storage Up to 45 Days
(1). Perform Daily PreFlight Check (Ref. A. Inspection During Storage
appropriate PFM or RFM).
(1). Where local average humidity exceeds
(2). Ensure that fuel cells are full (topped 40 percent, carefully inspect helicopter
off), and that oil in engine oil tank and every 15 days for corrosion. Perform
main, fan and tail rotor transmissions corrosion control as necessary (Ref. Sec.
is at FULL level (Ref. Sec. 120000). 204000). When inspecting for
corrosion, pay particular attention to
B. Storage those areas where moisture deposits do
not evaporate rapidly.
To maintain a flyable storage condition,
perform the following: (2). Where local average humidity is 40
percent or less, inspect for corrosion
(1). Perform Daily PreFlight Check (Ref. every 30 days.
appropriate PFM or RFM).
(3). If interior temperature of fuselage
(2). Perform ground runup at least once exceeds 160F (71C), ventilate helicop-
every five days (Ref. applicable PFM or ter by opening all doors and vents. If
RFM, Table 201, Sec. 010000). necessary, promote air circulation by
use of fans or other forced air equip-
(a). Start engine. After idle stabilizes, ment.
accelerate engine to 100 percent N2,
collective full down. Operate until oil (4). Ensure that fuel cells are full (topped
temperature is in normal operating off) and that rotor transmissions are at
range and ammeter indicates battery FULL level.
is fully charged.
(5). Drain fuel cell sump daily. (Replenish
(b). Shut down engine. fuel as necessary.)
(6). Check fuel and oil systems periodically
(c). Drain fuel cell sump (Ref. Sec.
for leakage. Replenish as necessary.
120000). (Replenish fuel as neces-
sary.) B. Storage
(d). Ensure that fuel shutoff valve is (1). Perform engine preservation according
closed (Ref. Sec. 280000). to applicable Allison Engine Operation
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102000 Revision 23
MAINTENANCE MANUAL
and Maintenance Manual (Ref. Table (8). Perform Daily PreFlight Check (Ref.
201, Sec. 010000) and current engine appropriate PFM or RFM).
service letters.
4. Storage Up to 6 Months
(2). Remove battery (Ref. Sec. 960500) A. Inspection During Storage
and store in cool, dry area.
(1). Perform same inspection as for 45 days
(3). If necessary, clean battery compartment of storage.
(Ref. Sec. 202000).
(2). Check main rotor, tail rotor and fan
(4). Ensure that fuel shutoff valve is closed blades for damage every 15 days (Ref.
(Ref. Sec. 280000). Chap. 62 and 64).
(3). Check areas around mooring attach-
(5). Clean entire helicopter.
ments for damage every 15 days.
(6). Inspect all drain holes (blades, fuselage, B. Storage
etc.) for obstructions and clear where
necessary.
Consumable Materials
(7). Open movable air vents in each door of (Ref. Section 910000)
cargo compartment; position opening in Item Nomenclature
each air vent downward. Close all other CM201 Protective coating
air vents. CM210 Corrosive preventive
CM729 Tape, masking, pressure sensitive
(8). Park and moor helicopter.
(9). Install a static ground. Special Tools
(10). Remove from area any objects that are Item Nomenclature
likely to strike helicopter during high ST2001 Pitot tube cover
wind conditions.
C. Return to Service (1). Perform engine preservation according
to applicable Allison Engine Operation
(1). Check that battery area is clean; then and Maintenance Manual (Ref. Table
install and connect battery (Ref. Sec. 201, Sec. 010000) and current
960500). applicable engine service letters.
(2). Check that fuel cells are full (Ref. Sec. (2). Drain engine oil system (Ref. Sec.
120000). 120000) and fill engine oil tank with
corrosion preventive (CM210).
(3). Remove covers and equipment used to
park and moor helicopter. (3). Remove battery (Ref. Sec. 960500)
and store it in cool, dry area.
(4). Inspect areas around mooring attach- (4). Clean battery compartment, if neces-
ments for damage. Repair damage as sary.
necessary.
(5). Ensure that fuel shutoff valve is closed
(5). Clean helicopter, as necessary. (Ref. Sec. 280000).
(6). Check that all drain holes in helicopter (6). Seal static source openings in engine
are free of obstructions. inlet fairing with masking tape
(CM729) and cover pitot tube with pitot
(7). Perform engine depreservation accord- tube cover (ST2001).
ing to applicable Allison Engine
(7). Clean entire helicopter.
Operation and Maintenance Manual
(Ref. Table 201, Sec. 010000) and (8). Inspect all drain holes (blades, fuselage,
current applicable engine service etc) for obstructions and clear them
letters. where necessary.
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MAINTENANCE MANUAL
(9). Spray or brush on the canopy and all (2). Remove masking tape from all external
windows a 0.008 inch (0.203 mm) access doors.
thickness of protective coating (CM201).
Cover and overlap all edges. Do not use steam or unautho-
CAUTION rized cleaning compounds to
(10). Inspect all external access doors for clean helicopter as damage to equipment
close fit. If doors are likely to admit may result.
moisture, seal edges with masking tape
(CM729). (3). Drain corrosion preventive from oil
tank and replenish with correct oil (Ref.
(11). Park and moor helicopter. Sec. 120000).
(12). Install a static ground. (4). Perform same procedures as for return
(13). Remove any objects from area that are to service after 45 days of storage.
likely to strike helicopter during high NOTE: Depreservation of engine fuel system
wind conditions. can usually be accomplished by making a
C. Return to Service normal start. (Ref. applicable Allison En-
gine Operation and Maintenance Manual,
(1). Carefully lift protective coating along Table 201, Sec. 010000 and current appli-
edges and peel it from canopy and cable engine service letters for engine de-
windows. preservation procedures.)
Page 203/(204 blank)

102000 Revision 23
MAINTENANCE MANUAL
Section
103000
Blade Folding
MAINTENANCE MANUAL
BLADE FOLDING
1. Main Rotor Blades Storage Rack (1). Verify that front and rear support
Description assemblies are complete and tight in all
details.
(Ref. Figure 201) (2). Visually inspect for missing nuts, bolts,
cushions, and shock cords.
(1). The main rotor blade storage rack
stows and secures the main rotor blades (3). Verify that no support tubing is bent.
on Model 369 helicopters during ground (4). Verify that plywood of rear support is
handling operations. The storage rack not split, cushions not torn, or nylon
consists of fore and aft units which, webbing harness not missing its buckle.
when installed, provide blade protection
for helicopters that cannot be placed in 3. Main Rotor Blades Folding and Unfolding
hangers or evacuated during adverse
weather conditions. The following paragraphs provide instruction
for operation of the main rotor blade storage
rack: For the unpinning of the main rotor
(2). The aft blade storage rack supports blades; for folding, unfolding, and repining of
three blades and consists of a plywood the blades. Adjustment and testing of main
blade rack which incorporates shock rotor flight controls, necessary after the blades
(bungee) cords and nylonwebbing have been repinned, is also covered here.
harness straps with buckles, pull tabs, (Ref. Sec. 204000 for information about
and a grommet. The aft storage rack is adjustment and corrosion protection of main
installed on the tailboom at Sta. 197.78, rotor blade attaching pins.)
just above the jack fitting. A decal on
the aft side of the storage rack facili- If main rotor blades are to re-
tates proper fore and aft positioning on CAUTION main folded for a considerable
the tailboom. The harness grommet length of time, main rotor hub must be cov-
engages the jack fitting and holds the ered with a suitable weatherresistant cov-
storage rack in position when the er.
harness straps are tightened and
secured. Shock cords secure the blades. NOTE: A mechanics assistant is needed for
blade folding and unfolding.
(3). The forward blade storage rack sup- A. Helicopter Location for Blade Folding
ports two blades and consists of a
plywood blade rack which incorporates (1). Locate helicopter slightly more than
shock cords, blade clamp (top blade rotor span from other aircraft or
only), rack support tubes, and landing vehicles.
gear clamps. The storage rack is (2). Park helicopter on the most level
installed forward of the fuselage so that ground available so that the load is
the blade clamp support is positioned balanced as much as possible.
left of the helicopter centerline. The
rack support tubes are secured with B. Main Rotor Blades Folddown Preparation
clamps to the landing gear just aft of
the skid tip lights. Shock cords secure Special Tools
the blades. (Ref. Section 910000)
Item Nomenclature
2. Main Rotor Blades Storage Rack ST2003 Main rotor blade storage rack
Inspection ST2004 Air inlet fairing cover
ST2005 Engine exhaust cover
(Ref. Figure 201)
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103000 Revision 23
MAINTENANCE MANUAL
(1). Inspect rack (Ref. Main Rotor Blades (a). Position rear blade support assembly
Storage Rack Inspection). on tailboom at Sta. 197.78, with its
lower step on left side of helicopter.
(2). Position main rotor so that one blade is
directly above and parallel to helicopter (b). Attach and secure straps. Adjust
tailboom. strap pull tabs so that harness
grommet engages jack fitting on
(3). Lock cyclic control stick (by applying tailboom.
friction) in the following positions:
(2). Install trailing rotor blade to aft storage
rack.
(a). Set collective pitch to mid position.
(a). Into center cushioned support step of
(b). Set longitudinal cyclic to full aft rear blade support assembly, position
position. trailing rotor blade (blade that is
directly above and parallel to tail-
(c). Set lateral cyclic to two thirds of total boom).
stick travel from full left toward full
right. Blade movement must be re-
CAUTION strained in the following steps
During blade folding, continual- to prevent damage since, with damper dis-
CAUTION ly monitor stick positions to engaged, the blade is free to pivot on blade
make sure no change occurs. Serious blade attaching pin.
damage may result from improper stick
placement. (b). Remove bolt or (alternatively)
attaching pin from damper arm of
(4). Disconnect wires or antennas (as trailing rotor blade, and move
applicable) at tailboom attach fitting, damper away from blade; replace bolt
and coil them. (or attaching pin) in damper arm.
(5). Cover (ST2004 and ST2005) engine air

NOTE: It is not necessary to remove a blade at-
taching pin in order to fold the first blade.
inlet and exhaust openings to prevent
entry of foreign objects during blade (c). Secure blade in support assembly
folding. with shock cord fastener.
During blade folding, use blade (3). Install remaining blades to aft storage
CAUTION support pole (ST2003). Prevent rack.
scratching of blade by attaching pins or
bolts. Avoid brushing of blades against one Blade movement must be re-
another or against any other surface. Lift
blade near tip to remove load on blade at- to prevent damage since, with damper dis-
taching pins. engaged, the blade is free to pivot on blade
attaching pin.
C. Aft Main Rotor Blades Folding
NOTE: The right blade goes to the top hold-
down position, and the left blade to the bot-
(Ref. Figure 201)
tom holddown position.
Special Tools
(a). Remove bolt or (alternatively)
Item Nomenclature
rotor blade, and move damper away
from blade; replace bolt (or attaching
ST2003 Main rotor blade storage rack pin) in damper arm.
(b). Unlock (but do not remove) blade
(1). Install aft storage rack (ST2003) to attaching pin that secures leading
helicopter. edge of blade to main rotor hub.
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MAINTENANCE MANUAL
(c). Unlock and remove blade attaching (d). Attach upper ends of support tubes to
pin that secures trailing edge of blade double blade support. Adjust tube
to leadlag link, and position cam length to proper height as required
handle vertically above pin. for extended or standard landing
gear. Secure with hardware provided.
(d). Instruct mechanics assistant using
bladesupport pole (ST2003) to guide (2). Install left forward blade to forward
rotor blade to its proper position on storage rack. Observe that one blade is
rear support assembly. directly above the left side of the front
(e). Secure blade in support assembly blade support assembly. Secure that
with shock cord fastener. blade in support with shock cord
fastener and hinged clamp fastener
(f). Reinstall blade attaching pin its support.
original position in leadlag link of
main rotor hub. NOTE: It is not necessary to remove blade at-
taching pins from the main rotor assembly
D. Forward Main Rotor Blades Folding or damper arm in order to secure this blade.
(Ref. Figure 201) (3). Install right forward blade to forward
storage rack.
Special Tools
(Ref. Section 910000) Blade movement must be re-
Item Nomenclature
ST2003 Main rotor blade storage rack to prevent damage since, with damper dis-
engaged, the blade is free to pivot on blade
attaching pin.
(1). Install forward storage rack (ST2003)
to helicopter. (a). Remove bolt or (alternatively)
(a). Position blade storage rack so that right forward blade and move damp-
top holddown position on rack is er away from rotor blade; replace bolt
approximately 15 degrees left of (or attaching pin) in damper arm.
helicopter centerline.
(b). Attach Ubolt clamp subassemblies (b). Unlock and remove blade attaching
to forward ends of each landing gear pin that secures trailing edge of blade
skid. Secure with hardware provided. to leadlag link, and position cam
Ensure that each Ubolt is attached handle vertically above pin.
ahead of curved portion of skid (but
(c). Instruct mechanics assistant using
aft of skid tip light) to assure ground
blade support pole to guide rotor
clearance.
blade to its proper position on right
NOTE: Top adjustment holes in support tubes side of double blade front support.
are for extended landing gear; bottom holes
are for standard landing gear. (d). Secure blade in support assembly
with shock cord fastener.
(c). Attach lower ends of support tubes to
Ubolt clamp brackets. Attach short (e). Reinstall blade attaching pin into its
tube to left skid. Secure with hard- original position in leadlag link of
ware provided. main rotor hub.
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103000 Revision 23
MAINTENANCE MANUAL
G103000
Figure 201. Folding and Stowing Main Rotor Blades
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Revision 23 103000
MAINTENANCE MANUAL
E. Main Rotor Blades Unfolding Preparation (1). Begin with the trailing blade, the one
supported by the center support step of
the rear blade support assembly.
Special Tools
(Ref. Section 910000) Blade movement must be re-
Item Nomenclature CAUTION strained in the following steps
ST2003 Main rotor blade storage rack to prevent damage since, with damper dis-
ST2004 Air inlet fairing cover
attaching pin.
ST2005 Engine exhaust cover
(a). Remove damper arm bolt or (alterna-
tively) attaching pin from damper
Before unfolding the main rotor blades, arm clevis. Extend and align damper
perform the following steps: arm with bolt hole in trailing edge of
blade. Insert bolt or attaching pin,
(1). Lock cyclic control stick, by applying but: If pin is used, do not lock pin at
friction, in the following positions: this time; if bolt is used, tighten to
torque of 30 60 inchpounds (3.39
(a). Set collective pitch to mid position. 6.78 Nm) and insert cotter pin.
(b). Set longitudinal cyclic to full aft (b). Remove shock cord fastener and
position. release blade from support.
(c). Set lateral cyclic to two thirds of total

NOTE: Only the damper arm attaching bolt (or
pin) was removed from this blade during
stick travel from full left toward full
folding, not a leadlag link attaching pin.
right.
(2). For the remaining aft secured rotor
During blade unfolding, contin- blades, proceed as follows:
CAUTION ually monitor stick positions to
make sure no change occurs. Serious blade Blade movement must be re-
damage may result from improper stick
placement. to prevent damage since, with damper dis-
(2). Cover (ST2004 and ST2005) engine air attaching pin.
inlet and exhaust openings to prevent
entry of foreign objects during blade (a). Remove shock cord fastener and
folding. release blade from support.
(b). Instruct mechanics assistant using
During blade unfolding, use
CAUTION blade support pole (ST2003). blade support pole (ST2003) to lift
and rotate blade forward to align
Prevent scratching of blade by attaching trailing edge of blade and attachment
pins or bolts. Avoid brushing of blades hole in leadlag link of main rotor
against one another or against any other hub (remove attaching pin from
surface. Lift blade near tip to remove load leadlag link to allow hole align-
on attaching pin. ment). Reinsert attaching pin (but
do not lock at this time).
F. Aft Main Rotor Blades Unfolding
(c). Remove damper arm bolt or (alterna-
(Ref. Figure 201) tively) attaching pin from damper
arm clevis. Extend and align damper
arm with bolt hole in trailing edge of
Special Tools
blade. Insert bolt or attaching pin
but: If pin is used, do not lock pin at
Item Nomenclature
this time; if bolt is used, tighten to
ST2003 Main rotor blade storage rack torque of 30 60 inchpounds (3.39
6.78 Nm) and insert cotter pin.
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103000 Revision 23
MAINTENANCE MANUAL
G. Forward Main Rotor Blades Unfolding H. Main Rotor Blades Storage Rack Removal
and Storage
(Ref. Figure 201)
(Ref. Figure 201)
Special Tools
(Ref. Section 910000) (1). Remove covers from engine exhaust
Item Nomenclature and air inlet fairing.
ST2003 Main rotor blade storage rack
(2). Unbuckle nylon webbing harness of
rear blade support assembly to disen-
(1). Begin with the blade stowed on the left gage aft blade storage rack from
side of the double blade front support tailboom. Further disassembly is not
assembly. No attaching pins were required.
removed from this blade for storage.
Release hinged clamp fastener support (3). Loosen or remove wing nuts to disen-
and shock cord fastener. Alignment is gage Ubolt clamp subassemblies from
not necessary. front end of landing gear skid assembly.
(2). For remaining forward rotor blade, Remove forward blade storage rack
proceed as follows: from helicopter.
Blade movement must be re- (4). Store blade storage racks.

to prevent damage since, with damper dis- (5). Reconnect any wires or antennas
engaged, the blade is free to pivot on blade disconnected for blade folding.
attaching pin.
(a). Remove shock cord fastener and 4. Main Rotor Flight Controls Adjustment
release blade from support. and Testing
(b). Instruct mechanics assistant using (Ref. Figure 201) Perform the following steps
blade support pole (ST2003) to lift after main rotor blades have been unfolded
and rotate blade aft to align trailing and repined.
edge of blade and attachment hole in
leadlag link of main rotor hub
(1). Lock all attaching pins and check that
(remove attaching pin from leadlag
locking force required to close pin
link to allow hole alignment). Rein-
handle is 25 35 pounds force (111.2
sert attaching pin (but do not lock at
155.7 N) (Ref. Sec. 621000 Main
this time).
Rotor Blade and Damper Attach Pin
(c). Remove damper arm bolt or (alterna- Installation and Adjustment, Sec.
tively) attaching pin from damper 621000).
arm clevis. Extend and align damper
arm with bolt hole in trailing edge of NOTE: Blade attaching pin handle is posi-
blade. Insert bolt or attaching pin, tioned behind retainer clip as shown.
but: If pin is used, do not lock pin at
this time; if bolt is used, tighten to (2). Loosen friction on cyclic and collective
torque of 30 60 inch pounds (3.39 sticks and check movement of controls
6.78 Nm) and insert cotter pin. through complete range of travel.
Page 206
Revision 23 103000
MAINTENANCE MANUAL
Chapter
11
Placards and
Markings
MAINTENANCE MANUAL
TABLE OF CONTENTS
110000 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Placards Exterior (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Placards Interior (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Placards Instrument Panels (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 212
Figure 204. Placards Optional Equipment (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 214
114000 Placards and Markings (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Exterior Placards and Markings (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . 202
Figure 202. Interior Placards and Markings (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 206
Figure 203. Instrument Panel Placards and Markings (Sheet 1 of 2) . . . . . . . . . 210
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
110000
Placards and
Markings
MAINTENANCE MANUAL
PLACARDS AND MARKINGS

1. General 2. Decal Application
(Ref. Figure 201 thru Figure 204 for placards (1). Where a decal overlaps or covers drain
and markings most common to 369D/E/FF holes, access doors, etc., the decal shall
500N Model Helicopters). Nomenclature be cut out to provide proper draining or
corresponds to that used in the IPC. (Ref. ease of opening or removing of doors,
Illustrated Parts Catalog for each decal part plates, etc.
number and the quantity required.) (2). Where a decal is applied over a skin lap
(one skin overlapping another), the
The following illustrations cover different decal must be cut so that it lies flat and
areas of decal placement on the helicopter: makes a positive bond.
(1). Exterior Figure 201. (3). Seal edges of all exterior decals, and
only those interior decals in the engine
(2). Interior Figure 202. compartment and cargo compartment
aft of the transmission, with epoxy
(3). Instrument panels Figure 203. adhesive. Edge sealing to be a mini-
mum of 1/32 inch (0.8mm) and a
(4). Optional equipment (various exterior maximum of 1/8 inch (3mm) around
and interior locations) Figure 204. perimeter of decal.
Page 201
110000 Revision 23
MAINTENANCE MANUAL
1 2
1
4
21
(NOTE 1) ROTATING
SWASHPLATE
SCISSORS DETAIL
INNER 6 CRANK CARGO
HANDLE 8 9 12 FLOOR
OUTER
HANDLE
11
5 10 JACK PAD
EXT. LH DOOR SHOWN

RH OPPOSITE 17 OIL CAP
15 16
(REF)
18
3
13 14 1
SHIP
CL
FAIRING
19
16 AIR
DUCT 20
(REF)
21
HEATER (NOTE 2)
DUCT FUEL CAP
(REF) (REF) 12 11
NOTES:
1. EFFECTIVE ON S/N:
369D; 001 AND SUBS.
369E; 001 300
369FF; 001 054
2. EFFECTIVE ON S/N:
369E; 301 AND SUBS
369FF; 055 AND SUBS
500N; 001 AND SUBS G1100001B
Figure 201. Placards Exterior (Sheet 1 of 5)
Page 202
Revision 23 110000
MAINTENANCE MANUAL
G1100002
Page 203
110000 Revision 23
MAINTENANCE MANUAL
CAUTION
PUSH DISCONNECT ELECTRICAL WIRING
BEFORE REMOVING BOOM
1. PUSH 2. ELECTRICAL
DISCONNECT
3. 500D / 500E / 530F / 520N

TO
LOCK
CAUTION
SAFELOCK
INNER HANDLE
IN POSITION
INSTALL THIS SIDE SHOWN BEFORE
TOWARD BLADES LOCKED FLIGHT
4. MAIN ROTOR 5. LOCKED TO

OPEN
6. OPEN AND LOCK, 7. LOCK BEFORE FLIGHT,

OUTER, LH & RH LH & RH
FULL
CAP. 0.4 U.S. PTS. JIG POINT
SEE FLT MANUAL
AND LOG BOOK CHECK LEVEL STA 92.64
FOR OIL USAGE
ADD
8. TAIL ROTOR 9. CHECK LEVEL 10. OIL LEVEL PLUG 11. JIG POINT
TRANSMISSION OIL
ATTACH JACK PAD THRU THRU
12. JACK PAD
THRU THRU
DANGER
LEFTHAND RIGHTHAND
LETTERS AND NUMERALS LETTERS AND NUMERALS
13. DANGER
14. RADIO CALL G1100003A
Page 204
Revision 23 110000
MAINTENANCE MANUAL
STATIC LINE
DRAIN VALVE
PUSH BOTTOM UP
THRU
16. STATIC LINE
15. RADIO CALL
17. OIL 18. NON SELFSEALING FUEL CELLS 18. SELFSEALING FUEL CELLS
FUEL 62.1 GALLONS FUEL 62.1 GALLONS
STATIC PORT
KEEP HOLES AND MCDONNELL DOUGLAS
SURFACE CLEAN
HELICOPTER CO. MESA, AZ
MODEL NO. 369
SERIAL NO.
TYPE CERT NO. H3WE
PROD CERT NO. 410
19. STATIC PORT 20. GROUND SYMBOL 21. MODEL IDENTIFICATION
WARNING
CAP. 12.0 U.S. PTS.
SEE FLT MANUAL DO NOT SUPPORT
TORQUE SCREWS AND LOG BOOK
TO 2025 INLB GEAR BOX WEIGHT FROM
FOR OIL USAGE DRIVE SHAFT COUPLING
22. HUB FAIRING 23. MAIN ROTOR 24. TAIL ROTOR

SCREW TORQUE TRANSMISSION OIL GEARBOX WARNING
ENGINE VENT
27. ENGINE VENT
25. FUEL DRAIN 26. OIL DRAIN
G1100004
Page 205
110000 Revision 23
MAINTENANCE MANUAL
28
30
30
2
29
31 1 32
33
1
28. CAUTIONCABLE 29. CAUTIONJACK LOAD 30. MODEL MUMBER
31. NO PUSH INFORMATION 32. LIGHT ACCESS 33. TRANSMISSION CHECK
G1100005
Page 206
Revision 23 110000
MAINTENANCE MANUAL
G1100021
Figure 202. Placards Interior (Sheet 1 of 5)
Page 207
110000 Revision 23
MAINTENANCE MANUAL
G1100022
Page 208
Revision 23 110000
MAINTENANCE MANUAL
NOTES:
1. NOT APPLICABLE TO 369D, SHIP
NO. 605 AND SUBSEQUENT,
2. NOT APPLICABLE TO 369E/FF 500N.
G1100023A
Page 209
110000 Revision 23
MAINTENANCE MANUAL
(369D; S/N 002 AND SUBS.)

(369E; S/N 001 THRU 383 )
(369FF;S/N 001 THRU 075)
(369D; S/N 002 AND SUBS.)

(369E; S/N 001 THRU 383 )
(369FF;S/N 001 THRU 075)
G1100024A
Page 210
Revision 23 110000
MAINTENANCE MANUAL
(369D: S/N 002 605)
G1100025A
Page 211
110000 Revision 23
MAINTENANCE MANUAL
SLIMLINE INSTRUMENT PANEL (369D)
G1100011A
Figure 203. Placards Instrument Panels (Sheet 1 of 2)
Page 212
Revision 23 110000
MAINTENANCE MANUAL
TINSTRUMENT PANEL (369MD)
TINSTRUMENT PANEL (369E/FF 500N)

G1100012A
Figure 203. Placards Instrument Panels (Sheet 2 of 2)
Page 213
110000 Revision 23
MAINTENANCE MANUAL
15
G1100031
Figure 204. Placards Optional Equipment (Sheet 1 of 4)
Page 214
Revision 23 110000
MAINTENANCE MANUAL
G1100032
Page 215
110000 Revision 23
MAINTENANCE MANUAL
G1100033
Page 216
Revision 23 110000
MAINTENANCE MANUAL
CARGO HOOK
FILTER BYPASS CONTROL EXTERNAL LOAD LIMIT EMERGENCY HOOK
PULL HANDLE FWD 2000 POUNDS RELEASE RELEASE
1. PARTICLE
2. 3. 4.
SEPARATOR
CARGO HOOK
ANTIICE
ANTIICE AIRFRAME
FUEL FILTER FUEL FILTER
INSTL INSTL AUTOREIGNITION
FOR GROUND FOR GROUND ARM
CAUTION: SPRING LOADED, DO NOT PUSH TEMP. OF 5 C OR TEMP. OF 5 C OR

LESS MAX. ALT. LESS. MAX. ALT.
5. FOURBLADED TAIL ROTOR 12,000 FT. 12,000 FT. OFF
PRESS TO RESET
FOR GROUND FOR GROUND
TEMP. GREATER TEMP. GREATER
7. AUTOMATIC
THAN 5 C MAX. THAN 5 C MAX.
ENGINE REIGNITION
ALT. 14,000 FT. ALT. 14,000 FT.
6. ANTIICE FUEL FILTER

WARNING
WARNING
FLOAT INFLATION ABOVE 81 KNOTS IAS
PITOT MAY BE HOT
AT LESS THAN 6000 FEET ALTITUDE,
DO NOT TOUCH EMERGENCY FLOATS
FLOAT LDG LT PRESS TO TEST
77 KNOTS IAS AT 6000 FEET AND ABOVE,
IS PROHIBITED
9. LANDING 10. AUXILIARY 11. WARNING

8. HEATED LIGHT FLOAT ELECTRICAL PANEL
PITOT TUBE
EMERGENCY FLOATS
NIGHT FLIGHT OVER MINIMUM FLOAT FILTER PRODUCTS DIVISION

WATER BEYOND OPERATIONAL Facet GREENSBORO, NC 27409
AUTOROTATION CAPABILITY PRESSURE IS
TO GROUND PROHIBITED 2.0 PSIG A. INSPECT RED BUTTON ON BOTTOM
OF BOWL FOR INDICATION OF FILTER
12. NIGHT FLIGHT 13. MIN. OPERATIONAL BYPASS.
RESTRICTION PRESSURE B. IF RED BUTTON IS NOT SHOWING
(ALSO EMERGENCY PROCEED WITH PREFLIGHT.
FLOATS) C. RED BUTTON SHOWING, RESET
BUTTON ONCE AND RUN ENGINE.
D. IF RED BUTTON REAPPEARS,
DISCONTINUE OPERATIONS AND IN
UTILITY FLOATS VESTIGATE REASON FOR FILTER
BYPASS INDICATION.
WARNING
14. ENGINE OIL SCAVENGE
USE CORRECT LOAD FILTER (MODEL D
RINGS, RINGS WITH AND E WITH A C20/R2
INTERNAL DIM. ENGINE CONVERSION
GREATER THAN
1.5 INCHES
CAN SLIP OFF
15. CARGO HOOK

P/N 171491 THRU 5
G1100034B

110000 Revision 23
MAINTENANCE MANUAL
Section
114000
Placards and
Markings (600N)
MAINTENANCE MANUAL
PLACARDS AND MARKINGS

1. General be cut out to provide proper draining or
ease of opening or removing of doors,
(Ref. Figure 201 thru Figure 203 for placards plates, etc.
and markings most common to Model 600N
helicopters). Nomenclature corresponds to that
used in the IPC. (Ref. Illustrated Parts Catalog
(2). Where a decal is applied over a skin lap
for each decal part number and the quantity
required.) (one skin overlapping another), the
decal must be cut so that it lies flat and
The following illustrations cover different makes a positive bond.
areas of decal placement on the helicopter:
(1). Exterior Figure 201. (3). Seal edges of all exterior decals, and
(2). Interior Figure 202. only those interior decals in the engine
compartment and cargo compartment
(3). Instrument panels Figure 203. aft of the transmission, with epoxy
adhesive. Edge sealing to be a mini-
2. Decal Application
mum of 1/32 inch (0.8mm) and a
(1). Where a decal overlaps or covers drain maximum of 1/8 inch (3mm) around
holes, access doors, etc., the decal shall perimeter of decal.
Page 201
114000 Revision 23
MAINTENANCE MANUAL
21 2
8
31
24
10
13 14 13 14
10
9
2 22 11
7
8 31
24 23
10
16
15
12
3
1
14 13 10 14 13
20
6
4 LOOKING
INBOARD 5
(LH SHOWN, RH OPP) 27
26
INSIDE ENGINE DOOR

(LH SHOWN, RH OPP)
29
28 25
LOOKING INBOARD
(LH SHOWN, RH OPP)
6G110101B
Figure 201. Exterior Placards and Markings (Sheet 1 of 4)
Page 202
Revision 23 114000
MAINTENANCE MANUAL
19 17
TOP VIEW
18 (4 PL)
30
BOTTOM VIEW
BOTTOM VIEW
6G110102
Page 203
114000 Revision 23
MAINTENANCE MANUAL
1. MCDONNELL DOUGLAS LOGO 2. 600N IDENTIFICATION

4. LOCKED
7. NO PUSH 3. DOOR
INSTRUCTIONS
5. LOCK BEFORE FLIGHT 6. WARNING 8. PUSH

LEFT AND RIGHT HAND SIDES 9. OIL
DURING OPERATIONS IN TEMPERATURES OF 40 _F (4 _C)

OR COLDER, FUEL ADDED TO THE TANK MUST CONTAIN
EITHER ANTI-ICING ADDITIVE PFA-55MB OR ANTI-ICING
ADDITIVE PER MIL-I-27868 OR MIL-I-85470 WITH A
MINIMUM CONCENTRATION OF .06% BY VOLUME
AND A MAXIMUM CONCENTRATION OF .15% BY VOLUME.
SEE FLIGHT MANUAL FOR MIXING PROCEDURES.
11. DECAL, FUEL 12. DECAL, ANTIICE ADDITIVE

13. JIG POINT
10. REGISTRATION NUMBER
14. ATTACH JACK PAD 15. PLATE IDENTIFICATION 16. GROUND SYMBOL 17. MAIN ROTOR
TRANSMISSION OIL
SERVICED
WITH
MOBIL
SHC
626
18. FUEL DRAIN 19. OIL USAGE 20. ELECTRICAL DISCONNECT

CAUTION
21. CAUTION CABLE
22. LIGHT ACCESS 23. TRANSMISSION CHECK 24. CAUTIONJACK LOAD
6G110103B
Page 204
Revision 23 114000
MAINTENANCE MANUAL
L O
O P
C E
K N
25. DECAL ARROW 26. DECAL ARROW 27. DECAL, LOCK 28. DECAL, OPEN
STATIC PORT
KEEP HOLES AND
SURFACE CLEAN
29. DECAL, LOCKED 30. DECAL, ENGINE VENT
31. DECAL, STATIC PORT
6G110104A
Page 205
114000 Revision 23
MAINTENANCE MANUAL
40 15 10
29 40 28
27 15
16 28
1 16
47 15
4
38
20 2
45 46
43 (4 PL)
44 (OPP)
7 (4 PL)
6
8
9 5
11
12
14
19
FS FORWARD AFT 13
113.85 FS DAMPER DAMPER
119.67
VIEW ROATED
LOOKING
17 OUTBOARD
17
LOOKING DOWN
PLAN VIEW OF CARGO FLOOR
18
4
16
LOOKING
CONVENIENCE OUTBOARD
INTERIOR PANEL
PANEL 18
VIEW LOOKING FORWARD

FROM CABIN INTERIOR
6G110111B
Figure 202. Interior Placards and Markings (Sheet 1 of 4)
Page 206
Revision 23 114000
MAINTENANCE MANUAL
36
21
25
22 23
24
37
VIEW LOOKING OUTBOARD

(UNDER COPILOTS SEAT)
4 TRANSMISSION 26
COVER
VIEW LOOKING AFT
42
41 VIEW ROTATED
35 32
34
39
LBL 5 RBL
6.00 CL 6.00
RIGHT FORWARD LOOKING AFT
VIEW LOOKING FWD AT

CANT STA 78.50
33 6G110112A
Page 207
114000 Revision 23
MAINTENANCE MANUAL
1. CABIN HEAT AND 2. OUTSIDE AIR 3. 24 VOLT DC 4. NO SMOKING/SEAT BELT 5. CONTROLS ACCESS DOOR
ENGINE ANTIICE TEMPERATURE WARNINGREPLACE DOOR
BEFORE FLIGHT
6. LEVEL HERE 8. LONGITUDINAL TRIM
11. FORWARD DAMPER 12. AFT DAMPER

WARNING WARNING
7. FUEL ACCESS DOOR 9. LATERAL TRIM 10. EXIT INSTRUCTIONS
14. FRICTION INCREASE
16. CAUTION SHOULDER HARNESS
17. DOOR
13. THROTTLE 15. EXIT INSTRUCTIONS
OPEN
19. LONG RANGE TANK CONNECTION

24. OIL TANK VENT
22. ENGINE OIL DRAINS
25. OIL TANK INLET
18. LOCK BEFORE EXIT 20. WARNING 21. MAIN ROTOR 23. OIL TANK OUTLET
TRANSMISSION OIL
COOLER DRAIN
6G110113
Page 208
Revision 23 114000
MAINTENANCE MANUAL
26. OIL LEVEL 27. ARROW 28. EXIT COCKPIT 29. OPEN FIRST
AIRCRAFT LIMITATIONS
XXXXXXXXXXXXXXXXX
32. DECAL, E1 35. DECAL, E12 47. DECAL, AIRCRAFT LIMITATIONS 41. DECAL, TB502
33. DECAL, E4 39. DECAL, TB5 42. DECAL, TB501

36. DECAL, E13
34. DECAL, E8 37. DECAL, K309
40. DECAL, EMERGENCY EXIT
O L
P O
E C
N K
43. DECAL ARROW 44. DECAL ARROW 45. OPEN DECAL 46. LOCK DECAL
AIRFRAME
FUEL FILTER
INSTL
20,000 FT MAX ALT
WHEN USING JET A,
JET A1, JP5,
OR JP8
14,000 FT MAX ALT

WHEN USING JET B
OR JP4
600N981131
47. AIRFRAME FUEL FILTER
6G110114B
Page 209
114000 Revision 23
MAINTENANCE MANUAL
VNE CARD HOLDER
OVSPD FAULT
TEST TEST
OFF OFF
2
1
1. RADIO CALL
2. CYCLIC FORCES
3. HELICOPTER LIMITATIONS
6G110121
Figure 203. Instrument Panel Placards and Markings (Sheet 1 of 2)
Page 210
Revision 23 114000
MAINTENANCE MANUAL
VNE CARD HOLDER
1. RADIO CALL
2. CYCLIC FORCES
3. HELICOPTER LIMITATIONS 6G110122
Figure 203. Instrument Panel Placards and Markings (Sheet 2 of 2)

114000 Revision 23
MAINTENANCE MANUAL
Chapter
12
Servicing
MAINTENANCE MANUAL
TABLE OF CONTENTS
120000 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Servicing (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Servicing (Special) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
A. Main Rotor Hub Wash Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
B. Main Rotor Blades Washing and Waxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
C. Engine Compressor Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3. Fuel System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
A. Fuel System Servicing Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
B. Approved Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
C. Fuel System Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
D. Fuel System Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
E. Fuel System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
F. Engine Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4. Engine Oil System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
A. Approved Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
B. Engine Oil Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
C. Engine Oil System Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
D. Engine Oil System Draining (Helicopters With Sta. 137.50 Bulkhead Drain
Ports Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
E. Engine Oil System Draining (Helicopters with Drain Valve Installed) . . . . . . . . 303
F. Engine Oil System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5. Main Rotor Transmission Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
A. Main Rotor Transmission Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Figure 301. Servicing Points Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . 304
Figure 302. Servicing Points Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . 305
B. Main Rotor Transmission Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
C. Main Rotor Transmission Oil System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
6. Tail Rotor Transmission Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
A. Tail Rotor Transmission Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
B. Tail Rotor Transmission Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
C. Tail Rotor Transmission Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
7. AntiTorque Fan Transmission Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
A. AntiTorque Fan Transmission Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
B. AntiTorque Fan Transmission Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
C. AntiTorque Fan Transmission Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Page i
MAINTENANCE MANUAL

8. OneWay Lock Control System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
9. Overrunning Clutch Servicing and Oil Leak Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 307
Figure 303. Checking Oil Level Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . 309
10. Miscellaneous Component Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
A. Rotor Brake Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
B. Landing Gear Damper Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
C. Component Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
D. Tail Rotor Swashplate Dual Bearings Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
E. Main Rotor Swashplate Bearing Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
F. Main Rotor Hub Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
G. Ground Handling Wheels Bearing Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
11. Overrunning Clutch Subassembly Bearing Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
12. Component Fluid Leak Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
A. Main Rotor Transmission or AntiTorque Transmission Oil Leaks . . . . . . . . . . . 311
B. Engine Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
C. Landing Gear Damper Hydraulic Fluid Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
D. OneWay Lock Hydraulic Fluid Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Figure 304. Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Page ii
MAINTENANCE MANUAL
Section
120000
Helicopter Servicing
MAINTENANCE MANUAL
HELICOPTER SERVICING
SERVICING
1. Servicing (General) Fuel Cell Capacities 600N
Servicing of helicopter includes replenishment Total Fuel . . . . . . . . . . . . 116.2 U.S. Gal. (440 Liters)
of fuel, changing or replenishment of oil and Usable Fuel . . . . . . . . . . 114.6 U.S. Gal. (434 Liters)
other such maintenance functions.
A. Fuel System Servicing Precautions
For locations of servicing points of standard
Comply with following precautions when
equipment Refer to Figure 301. For optional
servicing fuel system.
equipment servicing points Refer to
Figure 302. For lubrication points Refer to Turn off electrical switches
Figure 304. WARNING and disconnect any external
power from helicopter. Electrically
NOTE: The servicing intervals designated ground helicopter prior to refueling or
herein are the maximum allowable and defueling. Static discharge spark in
should not be exceeded. When unusual local presence of fuel vapors can cause fire
conditions such as environmental condi- or an explosion.
tions, utilization, etc., dictate, it is the pre-
rogative and responsibility of the operator to (1). Refueling vehicle should be parked a
increase the scope and frequency of the in- minimum of 20 ft. (6 M) from helicopter
spections as necessary to ensure safe opera- during fueling operation.
tion.
(2). Before starting fueling operation,
2. Servicing (Special) always ground fueling nozzle or fuel
truck to GROUND HERE receptacle or
Whenever helicopter operation has taken place to another bare metal location.
over or around salt water environments and
B. Approved Fuels
other environments found to be corrosive, the
following wash procedures must be performed. Service the helicopter with one of the autho-
rized fuels listed in the applicable Allison
A. Main Rotor Hub Wash Procedure Engine Operation and Maintenance Manual
(Ref. Main Rotor Hub Corrosion Prevention (Ref. Table 201, Sec. 010000). For operation
TriFlow Wash Procedure, Sec. 204000) under emergency conditions where authorized
fuel is not available, or for operation under
B. Main Rotor Blades Washing and Waxing cold weather conditions, refer to same manual.
(Ref. Main Rotor Blades Corrosion Arresting, C. Fuel System Filling

Sec. 204000) The fuel system has two fuel cells that are
interconnected for simultaneous flow and
C. Engine Compressor Wash venting. Fuel system filler is on right side of
(Ref. Chap. 71 and applicable Allison Engine helicopter.
Operation and Maintenance Manual, Table (1). Refuel helicopter with correct fuel as
201, Sec. 010000) soon after landing as possible to
prevent moisture condensation and to
3. Fuel System Servicing keep helicopter as heavy as possible in
Fuel Cell Capacities 369D/E/FF 500N case of winds.
NonselfSealing . . . . . 64.0 U.S. Gal. (242 Liters) (2). Keep fueling nozzle free of all foreign
Usable Fuel . . . . . . 62.7U.S. Gal. (237 Liters) matter.
SelfSealing . . . . . . . . . 62.0 U.S. Gal. (234 Liters) (3). Check filler cap for security after
Usable Fuel . . . . . . 60.7 U.S. Gal. (229 Liters) fueling.
Page 301
120000 Revision 23
MAINTENANCE MANUAL
D. Fuel System Draining NOTE: If the type of engine oil or the oil group
is changed, remove and inspect the oil filter
Fuel draining should be accomplished with each 25 hours of engine operation (Ref.
helicopter as level as possible. applicable Allison Engine Operation and
Maintenance Manual for further informa-
(1). Fuel system may be defueled in either tion).
of two ways:
B. Engine Oil Changing
To avoid possible damage to fuel (Ref. Applicable Allison Engine Operation and
CAUTION pump, do not operate fuel pump Maintenance Manual, Table 201, Sec.
with fuel tanks drained. 010000)
C. Engine Oil System Filling
(a). Defuel through filler port using a
pump. The engine oil tank filler is on the right side of
the helicopter. A liquid level sight gauge for
(b). Open system drain valves on fuselage checking oil level in tank is visible through a
underside and in engine compart- transparent window near the filler.
ment. NOTE:
(2). Fuel supply line drain valves are spring D Before adding oil, the oil container must
loaded type and open by pushing valve be shaken to ensure proper mixture of the
and attached drain line. antifoaming additive.
D If sight gauge does not permit positive de-
(3). Fuel cells drain valve is springloaded termination, remove filler cap and visual-
closed and is opened by pressing ly check the oil level.
internal plunger. (1). Check oil level within 15 minutes of
engine shutdown; replenish if low.
E. Fuel System Bleeding
(2). If engine oil level is low after helicopter
(Ref. Chap. 28 and applicable Allison Engine has set for more than 15 minutes;
Operation and Maintenance Manual, Table (a). Run engine for at least 1 minute at
201, Sec. 010000) Purge entrapped air from ground idle.
the fuel system, if necessary.
Ensure engine oil pressure is at-
CAUTION
F. Engine Fuel Filter Replacement tained when starting engine
(Ref. applicable Pilots Flight Manual).
(Ref. Applicable Allison Engine Operation and (b). Shut down engine, check oil level,
Maintenance Manual, Table 201, Sec. replenish if low.
010000)
NOTE:
4. Engine Oil System Servicing D Motoring engine can draw oil from the oil
tank to the gearbox, giving low oil level
Oil Tank Capacity . . . . 3.0 U.S. Qt. (2.84 Liter) indications.
D If engine oil level indicates a low condi-
A. Approved Lubricants
tion after setting overnight, engine check
valve may be leaking oil from tank to en-
Service the helicopter with one of the autho-
gine gearcase.
rized oils listed.
(3). Ensure oil tank filler cap is securely
For operation under emergency conditions tightened immediately after servicing.
where different oils must be mixed, or for
D. Engine Oil System Draining (Helicopters
operation under cold weather conditions, use
With Sta. 137.50 Bulkhead Drain Ports
alternate lubricants (Ref. applicable Allison
Installed)
Engine Operation and Maintenance Manual,
Table 201, Sec. 010000). (1). Open engine access doors.
Page 302
Revision 23 120000
MAINTENANCE MANUAL
(2). Place suitable container under engine (1). Drain oil from engine, oil tank and oil
oil tank drain and remove engine oil cooler (Ref. Engine Oil System Drain-
tank filler cap. ing).
(3). Remove engine oil tank drain cap. (2). Replace engine oil filter(s) (Ref. Appli-
cable Allison Operation and Mainte-
(4). After draining oil from tank, reinstall nance Manual).
engine oil tank drain cap and filler cap.
(3). Refill engine oil system (Ref. Engine Oil
(5). To drain residual oil from engine System Filling).
accessory gearbox drain, remove wire
lead and lower chip detector. Use (4). Operate engine for five minutes and
suitable container to catch oil. Check repeat above procedures.
that detector Oring is serviceable 5. Main Rotor Transmission Servicing
(replace as required); reinstall detector;
torque to 50 60 inchpounds (5.65 Service the helicopter with one of the autho-
6.78 Nm); lockwire and reconnect wire rized oils listed (Ref. Sec. 910000).
lead. NOTE: Mobil oil SHC 626 can be formulated
E. Engine Oil System Draining (Helicopters such that it may have two different colors.
with Drain Valve Installed) The oil can still be mixed with no adverse af-
fects.
(1). Remove interior trim and aft bulkhead
Main Transmission Capacities
right access cover.
369D25100 . . . . . . . . . . 12.0 U.S. Pt. (5.67 Liter)
(2). Place a suitable container under 369F5100 . . . . . . . . . . . 14.0 U.S. Pt. (6.62 Liter)
overboard oil drain line where it exits
A. Main Rotor Transmission Filling
fuselage underside at firewall.
Transmission (gearbox) oil should be replaced
(3). Remove cap from engine oil tank filler. with new oil whenever it is drained. A liquid
Pull out knurled springloaded button level sight gauge for checking main rotor
to open valve in engine oil drain line transmission oil level is located on the
just below engine oil cooler (Ref. righthand side and visible through the clear
Figure 301). Rotate button and valve panel of the main transmission interior cover.
poppet so that locking pin rests on
shoulders of pin slot. NOTE:
D Replacement of oil pump filter (Ref. Sec.
(4). After draining oil from tank, reinstall
632100) is required after oil is drained
filler cap and close oil drain valve;
from main rotor transmission and at in-
ensure that poppet pin is in stop slot.
tervals specified (Ref. Sec. 052020).
(5). Reinstall access cover and interior trim. D If oil was drained from transmission cool-
er, groundoperate helicopter for 15 min-
(6). To drain residual oil from engine utes after replenishing oil (Ref. applicable
accessory gearbox drain, remove wire PFM, Table 201, Sec. 010000). Recheck
lead and lower chip detector (Ref. Sec. oil level at liquid level sight gauge and re-
790000). Use suitable container to plenish as necessary. This purges air from
catch oil. Check that detector Oring is oil cooling system and ensures that entire
serviceable (replace as required); oil cooling system is full.
reinstall detector, torque to 50 60
inchpounds (5.65 6.78 Nm) and (1). Replenish with correct oil until oil level
reconnect wire lead. is at FULL on sight gauge by lifting
breatherfiller cap and inserting spout
F. Engine Oil System Flushing of oil can into opening.
The following procedure is for flushing oil that (2). Check that springloaded cap closes
has been contaminated or when changing the when oil can spout is removed. Replace
type of oil. trim cover.
Page 303
120000 Revision 24
MAINTENANCE MANUAL
BATTERY ELECTROLYTE
WATER
MAIN XMSN FILLER

MILL23699/SHC 626
PF NOTE 1
EXTERNAL POWER
RECEPTACLE
ONEWAY LOCK
RESERVOIR MILH5606
FUEL FILTER 5 MICRON
FUEL CELL SUMP DRAIN
L/G DAMPERS, 4 PLACES FUEL SYSTEM FILLER ENGINE OIL TANK FILLER
NITROGEN/MILH5606 JP4/JP5 MILL23699
PF PF NOTE 2 PF NOTES 1, 2
FAN XMSN FILLER FAN GEARBOX

MILL23699/SHC 626 DRAIN (500/600N)
PF ENGINE OIL
NOTE 1
TRANS. OIL COOLER DRAIN
COOLER DRAIN ENGINE OIL
TANK DRAIN
OIL DRAINS FOR MAIN TRANSMISSION, ENGINE OIL COOLERS,

NOTES: ENGINE OIL TANK AND FAN GEARBOX
1. DO NOT MIX OILS.
2. REFER TO APPLICABLE ALLISON OPERATION MAINTENANCE
MANUAL FOR FREQUENCY OF OIL CHANGE, AUTHORIZED
FUELS AND OILS AND SERVICE CHECKS.
FAN TRANSMISSION
FREQUENCY SYMBOL REQUIREMENTS
BREATHER FILLER
MILL23699/SHC 626
DAILY . . . . . . . . . . . 1. INSPECT PRIOR TO FIRST FLIGHT OF THE DAY
PF NOTE 1
PF PREFLIGHT . . . . . . . 1. INSPECT PRIOR TO EACH FLIGHT
100 HOURS . . . . . . . 1. REMOVE BATTERY AND SERVICE PER THE MANUFACTURERS

MAINTENANCE MANUAL
2. INSPECT AND REPLENISH ONEWAY LOCK RESERVOIR AS
APPLICABLE
YEARLY . . . . . . . . . . 1. DRAIN AND REFILL T/R GEARBOX, FAN TRANSMISSION
300 HRS / YEARLY . . 2. DRAIN AND REFILL 369D25100 M/R G/B SERVICED WITH MILL23699;
REPLACE OIL FILTER ELEMENT
600HRS / YEARLY . . 3. DRAIN AND REFILL 369D25100 M/R G/B SERVICED WITH MOBIL SHC626
OR 369F5100 M/R G/B; REPLACE OIL FILTER ELEMENT
TAIL ROTOR 3. REPLACE ENGINE FUEL FILTER (5 MICRON)
TRANSMISSION ON CONDITION . . . . 1. ON CONDITION OR EVERY 9 MONTHS IF ON SHELF
G120001C
Figure 301. Servicing Points Standard Equipment
Page 304
Revision 34 120000
MAINTENANCE MANUAL
ROTOR BRAKE RESERVOIR

MILH5606
MIST ELIMINATOR
PARTICLE SEPARATOR
ANTIICE FILTER SCAVENGE OIL FILTER
NOTE
NOTE:
APPLICABLE TO ALL ALLISON 250C20R/2 AND C47 ENGINES.
OPTIONAL EQUIPMENT FOR ALLISON 250C20B, C30 ENGINES.
REFER TO ALLISON OPERATION AND MAINTENANCE MANUAL
FOR FILTER ELEMENT REPLACEMENT SCHEDULE.
FREQUENCY SYMBOL REQUIREMENT

100 HOURS . . . . . . . . . 1. CHECK ROTOR BRAKE RESERVOIR FOR
PROPER LEVEL; REPLENISH IF LOW.
. . . . . . . . . . . . . . . . . . . 2. REMOVE AND CLEAN THE MIST

ELIMINATOR.
NOTE . . . . . . . . . . . . . 3. REPLACE SCAVENGE OIL FILTER ELEMENT.
300 HOURS . . . . . . . . . 4. REPLACE ANTIICE FILTER ELEMENT.
. . . . . . . . . . . . . . . . . . . 5.
REMOVE AND CLEAN PARTICLE
SEPARATOR ASSEMBLY.
SERVICING MATERIAL
SPEC: MATERIAL: REF:
MILL23699 LUBRICATING OILS TABLE 1, 910000
MOBIL SHC 626 ITEMS CM125 & CM126
JET A/JP4/JP5/JP8 ENGINE FUEL, TURBINE TABLE 201, 010000

ALLISON OPERATION AND MAINTENANCE
MANUAL
MS36300 OR 0B41 DISTILLED WATER ANY SOURCE ACCEPTABLE
DRY NITROGEN OR EQUIVALENT ANY SOURCE ACCEPTABLE

G120002B
Figure 302. Servicing Points Optional Equipment
Page 305
120000 Revision 26
MAINTENANCE MANUAL
B. Main Rotor Transmission Draining 6. Tail Rotor Transmission Servicing

Special Tools rized oils listed (Ref. Table 1, Sec. 910000).
(Ref. Section 910000) NOTE: Mobil oil SHC 626 can be formulated
Item Nomenclature such that it may have two different colors.
ST301 Main transmission drain hose The oil can still be mixed with no adverse af-
fects.
Tail Rotor Transmission Capacity
(1). Remove main rotor transmission cooler 369D25300 . . . . . . . . . . 0.530 U.S. Pt. (0.250 Liter)
drain cap and drain oil into suitable
369D25400 . . . . . . . . . . 0.530 U.S. Pt. (0.250 Liter)
container.
A. Tail Rotor Transmission Filling
(2). Remove main rotor transmission drain Tail rotor transmission oil should be replaced
access covers, wire leads and chip with new oil whenever it is drained. A liquid
detectors. level sight gauge for checking oil level is
located on the transmission housing.
(3). Using main rotor transmission drain
hose (ST301), drain oil into suitable (1). Check oil level.
container. (2). Remove lockwire and unscrew brea-
therfiller cap.
(4). If damaged, replace Orings used with
chip detectors and selfclosing valves. (3). Fill with proper oil by pouring oil into
transmission until oil level shows
FULL on sight gauge.
(5). If removed, reinstall selfclosing valve.
Torque valve to 50 60 inchpounds (4). Check that filler Oring is serviceable
(5.65 6.78 Nm) and chip detector to (replace if necessary). Reinstall brea-
40 50 inchpounds (4.52 5.65 therfiller and torque to 45 55
Nm). Lockwire valve to gearbox and inchpounds (5.08 6.21 Nm) with
detector to valve. Reconnect wire leads. breather hole aft (Ref. Sec. 632510)
at completion of torquing. Secure with
(6). Reinstall main rotor transmission lockwire.
access covers. B. Tail Rotor Transmission Draining
C. Main Rotor Transmission Oil System (1). Position suitable container under tail
Flushing rotor transmission drain.
(2). Remove wire lead, lockwire, chip
The following procedure is for flushing oil that detector and selfclosing valve (Ref.
has been contaminated or when changing the Sec. 632510).
type of oil.
(3). If damaged, replace Orings used with
(1). Drain oil from transmission and oil chip detector and selfclosing valve.
cooler (Ref. Main Rotor Transmission (4). After oil drains, install selfclosing
Draining). valve. Torque valve to 50 60 inch
pounds (5.65 6.78 Nm) and chip
(2). Replace transmission oil filter (Ref. Sec. detector to 40 50 inchpounds (4.52
632100, Main Transmission Filter 5.65 Nm). Lockwire valve to gearbox
Replacement). and detector to valve; reconnect wire
leads.
(3). Refill transmission oil system (Ref.
Main Rotor Transmission Filling). C. Tail Rotor Transmission Flushing
The following procedure is for flushing oil that
(4). Operate aircraft for five minutes, shut has been contaminated or when changing the
down and repeat steps (1). thru (3). type of oil.
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Revision 24 120000
MAINTENANCE MANUAL
(1). Drain oil from tail rotor transmission transmission drain and remove cap.
(Ref. Tail Rotor Transmission Drain- (Ref. Figure 301).
ing).
(4). After draining oil from transmission,
(2). Refill tail rotor transmission (Ref. Tail reinstall drain cap.
Rotor Rotor Transmission Filling).
C. AntiTorque Fan Transmission Flushing
(3). Operate aircraft for five minutes, shut The following procedure is for flushing oil that
down and repeat steps (1). and (2). has been contaminated or when changing the
type of oil.
7. AntiTorque Fan Transmission Servicing
(1). Drain oil from fan transmission (Ref.
Service the helicopter with one of the autho- AntiTorque Fan Transmission Drain-
rized oils listed (Ref. Sec. 910000). ing).
NOTE: Mobil oil SHC 626 can be formulated (2). Refill fan transmission (Ref. Anti
such that it may have two different colors. Torque Fan Transmission Filling).
The oil can still be mixed with no adverse af-
fects. (3). Operate aircraft for five minutes, shut
down and repeat steps (1). and (2).
Fan Transmission Capacity . . . . 8 U.S. Oz. (236 cc)
8. OneWay Lock Control System Servicing
A. AntiTorque Fan Transmission Filling
Antitorque fan transmission oil should be rized hydraulic oils listed (Ref. Sec. 910000).
replaced with new oil whenever it is drained. A
liquid level sight gage for checking oil level is OneWay Lock Capacity . . . . 0.67 U.S. Oz. (20 cc)
located on the transmission housing. (1). To check oil level, remove control access
(1). Check oil level. cover.
NOTE: Reservoir should be 1/2 to 3/4 full.
(2). If servicing is required, remove fan
inlet screen and fan hub transmission (2). If oil level in reservoir is low, lift filler
fairing. cap and add oil as needed.
(3). Remove lockwire and remove filler (3). Reinstall pilots seat cover.
plug.
NOTE: If oil level is consistently low, oneway
(4). Fill by pouring oil into transmission lock should be repaired to stop oil leakage
filler plug hole, until oil level shows (Ref. Component Overhaul Manual).
FULL on sight gauge.
9. Overrunning Clutch Servicing and Oil
(5). Check that plug Oring is serviceable Leak Analysis
(replace as required). Reinstall filler
plug and torque to 45 55 inch (Ref. Figure 303) When oil leakage or seepage
pounds (5.08 6.21 Nm). Secure with is noticed at oil seals or assembly joint lines of
lockwire. overrunning clutch, clutch requires further
inspection and investigation as follows.
B. AntiTorque Fan Transmission Draining
NOTE: Mobil oil SHC 626 can be formulated
(1). Remove fan inlet screen and transmis- such that it may have two different colors.
sion fairing. The oil can still be mixed with no adverse af-
fects.
(2). Cut lockwire and remove fan transmis- Overrunning Clutch Capacities
sion filler plug.
369A535011, 21, 31 . . . . . . 1.52 U.S. Oz. (45cc)
(3). Open engine access doors and place 369A535041, 51 . . . . . . . . . 1.01 U.S. Oz. (30 cc)
suitable container under the fan 369F5450 . . . . . . . . . . . . . . . . 3.64 U.S. Oz. (110 cc)
Page 307
120000 Revision 24
MAINTENANCE MANUAL
(b). Read scale to determine oil level and

Consumable Materials servicing required. Full oil level is
(Ref. Section 910000) indicated by oil level of 2 7/8 inches
Item Nomenclature (7.30 cm) on scale. Minimum allow-
CM112 Antiseize compound high temperature able quantity (13 cc) is 7/8 inch
(22.23 mm) on scale. Recheck reading
CM125 Oil a minimum of three times.
CM126 Oil, turbine
If oil quantity is less than 7/8
CAUTION inch (22.23 cm) on scale, the
CAUTION clutch subassembly must be removed and
inspected for evidence of overheating (Ref.
D Checking clutch oil level requires removal CSPDEF5).
of main rotor transmission drive shaft.
Use care not to stress drive shaft dia- (6). For a 369F5450 clutch, there is two
phragms (early type) or flexible couplings methods for checking the oil level:
(current type) during removal and instal-
lation. Deflection in these areas are lim-
ited due to material hardness. (a). First Method: Full oil level is indi-
cated by oil level of 3 1/8 inches (9.84
D The 369F5450 clutch is only to be serviced cm) on a 6 inch (15 cm) machinists
with Mobil SHC 626 oil (CM125). scale, 1/2 inch (12.7 mm) width,
D The 369A5350 clutch is only to be ser- inserted into clutch exactly 5 inches
viced with MILL23699 oil (CM126). (12.7 cm). Minimum allowable
quantity (60 cc) is 5/8 inch (15.88
(1). Remove trim and blower access door. mm) on scale. Recheck reading a
minimum of three times.
(2). Remove main rotor transmission drive
shaft (Ref. Sec. 631000). Carefully (b). Second Method: Full oil level is
slide shaft from drive couplings; do not indicated by oil level of 4 5/8 inches
strike shaft against any object. (11.77 cm) on a 12 inch (30 cm)
machinists scale, 1/2 inch (12.7 mm)
(3). Remove coupling bolt and Oring from width, inserted to bottom of inner
end of clutch. race. Minimum allowable quantity
(60 cc) is 2 1/8 inch (5.40 cm) on
(4). Check that the three drain holes in scale. Recheck reading a minimum of
clutch housing are clean and free of three times.
obstruction. Oil leakage may indicate
engine power output seal leakage if If oil quantity is less than 5/8
clutch oil level is checked and within CAUTION inch (15.88 mm) on scale for the
limits. first method or 2 1/8 inches (5.40 cm) for the
second method, the clutch subassembly
(5). For a 369A5350 Clutch: must be removed and inspected for evidence
of overheating.
(a). Using a clean 6 inch (15 cm) machi-
nists scale, 1/2 inch (12.7 mm) width,
slowly insert scale into center of (7). Service clutch with lubricating oil
clutch output shaft until scale (CM125 or CM126). If oil level readings
bottoms. Scale must be inserted 4 7/8 indicate less than full level. Do not
inches (12.38 cm). overfill. Recheck oil level as in previous
step.
NOTE: Trim edge of scale as required to reduce
width of scale and allow scale to bottom in NOTE: Always check oil level after installing
clutch. clutch in the helicopter.
Page 308
Revision 26 120000
MAINTENANCE MANUAL
CLUTCH CENTERLINE CLUTCH OUTPUT SHAFT
SCALE CLUTCH
MINIMUM OIL LEVEL
FULL OIL LEVEL 7/8 IN. (22.23 MM)
27/8 IN. (7.30 CM)
ENGINE
47/8 IN. (12.38 CM)

SCALE BOTTOMED
COUPLING
DRAIN HOLES
ORING
COUPLING 369A5350 CLUTCH OIL
MAIN TRANSMISSION LEVELS SCALE INDICATIONS
DRIVE SHAFT
COUPLING BOLT
CLUTCH CENTERLINE
SCALE
ENGINE
3 1/8 IN. FULL" OIL LEVEL
CLUTCH CENT-
(9.84 CM) 110 CC
ERLINE
5/8 IN. MINIMUM OIL LEVEL

SCALE (15.88 MM) 60 CC
4 5/8 IN. FULL" OIL LEVEL ENGINE

(11.77 CM) 110 CC
2 1/8 IN. MINIMUM OIL LEVEL

(5.40 CM) 6 INCH (15 CM) SCALE METHOD
60 CC
12 INCH (30 CM) SCALE METHOD
369F5450 CLUTCH
OIL LEVELS SCALE INDICATIONS
G123001B
Figure 303. Checking Oil Level Overrunning Clutch
Page 309
120000 Revision 23
MAINTENANCE MANUAL
(8). If coupling shimming was disturbed, C. Component Lubrication Chart

shim coupling so that there is
0.0350.055 inch (0.8891.397 mm) (Ref. Figure 304 for required lubrication
Oring gap. (Ref. Sec. 631000 for points, lubricants to be used, and lubrication
clutch installation and shimming intervals.)
requirement details.) Use extreme care when apply-
CAUTION ing any type of lubrication
When installing clutch coupling
CAUTION bolt in next step, installation
(grease, oil, dryfilm, etc) in vicinity of te-
flon bearings. Most lubricants allow a dirt
torque on the bolt must not be less than 250 retaining film to form or have other detri-
300 inchpounds (28.25 33.90 Nm) mental effects that can cause rapid
plus drag torque. Torquing to lower value deterioration of bearing surface.
reduces clutch bearing clampup and may
result in bearing race spinning. D. Tail Rotor Swashplate Dual Bearings
Repack
(9). Coat bolt threads with oil (CM112).
Install coupling bolt and Oring (Drag Check ball bearing for excessive loss of grease
torque for bolt selflocking serviceabili- and serviceability and relubricate (repack)
ty is 25 inchpounds (2.82 Nm) (Ref. Sec. 643000).
minimum, 200 inchpounds (22.60 E. Main Rotor Swashplate Bearing Repack
Nm) maximum). Torque bolt to 250
300 inchpounds (28.25 33.90 Nm) Check seals for evidence of deterioration and
plus actual drag torque. grease leakage. Inspect bearing assembly for
serviceability and repack (Ref. COM, Sec.
(10). Position main rotor transmission drive 623010).
shaft between drive couplings. Install
four bolts and washers each end of F. Main Rotor Hub Tapered Bearings
drive shaft and torque bolts to 50 75 Clean, inspect, and relubricate (repack). (Ref.
inchpounds (5.65 8.47 Nm). Sec. 622000).
(11). Reinstall blower access door and trim. G. Ground Handling Wheels Bearing Repack
10. Miscellaneous Component Servicing Consumable Materials

A. Rotor Brake Servicing Item Nomenclature
CM111 Grease, aircraft
(Ref. Sec. 632200 for information on adding
hydraulic fluid to the rotor brake master
cylinder and bleeding the hydraulic system.) At regular intervals, repack wheel bearings
with grease (CM111).
B. Landing Gear Damper Servicing
11. Overrunning Clutch Subassembly Bearing
Servicing of the landing gear damper is Repack
performed by overhauling the damper assem- For 369A5350 overrunning clutch, repack
bly, or if equipped with schrader valve, bearing per CSPCOM5, Sec. 631010.
servicing with nitrogen if it does not meet the
minimum extension requirements (Ref. For 369F5450 overrunning clutch, repack
321000). bearing per CSPCOM5, Sec. 631015.
Page 310
Revision 32 120000
MAINTENANCE MANUAL
12. Component Fluid Leak Analysis 010000) for definition of permissible engine
oil leakage.
A. Main Rotor Transmission or AntiTorque
Transmission Oil Leaks C. Landing Gear Damper Hydraulic Fluid
Leak
Oil leakage, seepage, or capillary wetting at oil
seals or assembly joint lines of main or Hydraulic fluid leakage from any of landing
antitorque transmissions are permissible if gear dampers is not permissible. If leakage is
leakage rate does not exceed 2 cc per hour (one present, damper assembly should be over-
drop per minute). An acceptable alternate rate hauled (Ref. Component Overhaul Manual) as
of leakage from either transmission is, if oil required and a serviceable unit installed. If
loss is not more than from the full to the add leaking landing gear damper is not replaced
mark on the sight gauge within 25 flight hours when leakage is noticed, continuation of
(Repair leaks according to instructions in damper in service can result in unequal and/or
Component Overhaul Manual). unacceptable dampening and/or ground
NOTE: resonance.
D On gearbox oil seals with less than 2 NOTE: It is normal for a thin hydraulic oil film
hours of operation, some seepage or wet- to remain on damper piston as a result of
ting of adjacent surfaces is normal until wiping contact with piston seal. Newly in-
seal is wetted and wornin (seated). If stalled dampers may also have slight oil
seepage continues at rate of one drop per seepage from oil trapped in end cap threads
minute or less, seal may be continued in during damper assembly. Neither of these
service. Check transmission oil level and should be considered damper leakage or
observe seepage rate after every 2 hours cause for damper replacement.
of operation. Shorter inspection periods
may be required if seal leakage appears to D. OneWay Lock Hydraulic Fluid Leak
be increasing.
Hydraulic fluid leakage from any part of
D If excessive gearbox oil seepage occurs, oneway lock is not permissible. When leakage
check breather filler for proper installa- is observed, assembly should be overhauled
tion and operation (Ref. Component Over- (Ref. Component Overhaul Manual) as
haul Manual for cleaning procedures). required and a serviceable unit installed. If
B. Engine Oil Leaks leaking oneway lock is not replaced when
leakage occurs, continuation in service may
(Ref. Applicable Allison Engine Operation and result in mechanical malfunction that could be
Maintenance Manual (Ref. Table 201, Sec. hazardous to flight safety.
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MAINTENANCE MANUAL
(NOTE 2)
(NOTE 5)
(NOTE 3)
(NOTE 4)
(NOTE 3)
(NOTE 1)
SYMBOL SPECIFICATION
300 HOURS
NOTES:
1200 HOURS 1. T/R SWASHPLATE DUPLEX BEARINGS
2. M/R SWASHPLATE BEARING
2770 HOURS OR 2 YEARS 3. M/R HUB TAPERED BEARINGS
4. OVERRUNNING CLUTCH ASSEMBLY UPPER BEARINGS
HAND PACK 5. YSAS ACTUATOR
SPECIAL TOOL RECOMMENDED G120003A
Figure 304. Lubrication Chart
Page 312
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MAINTENANCE MANUAL
Chapter
18
Vibration and Noise
Analysis
MAINTENANCE MANUAL
TABLE OF CONTENTS
181000 Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Main Rotor Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Rotor Hub Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Balancing Equipment and Balance Spare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Isolating Tracking Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Main Rotor System Tracking Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Magnetic Pickup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Tracking Tip Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
D. Main Rotor System Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Blade Tracking Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Main Rotor Balancing Equipment Installation . . . . . . . . . . . . . . . . . . 404
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Blade Tracking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Typical Track Conditions and Adjustments . . . . . . . . . . . . . . . . . . . . . 501
A. Blade Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
B. Pitch Control Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
C. Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
D. Main Rotor Ground Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
E. Hover Track Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
F. Forward Flight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
2. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
3. Main Rotor System Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4. Main Rotor Autorotation RPM Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
5. Main Rotor Hub Balancing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Table 501. Summary Procedure for Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . 507
Table 502. Autorotation Rpm Chart (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Table 503. Autorotation Rpm Chart (369FF/500N) . . . . . . . . . . . . . . . . . . . . . . . . . 508
Figure 503. Main Rotor Hub Balancing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Figure 504. Main Rotor Hub Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
181060 Main Rotor Track and Balance (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

2. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Balancing Equipment and Balance Spare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Isolating Tracking Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1. Main Rotor System Tracking Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Magnetic Pickup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Blade Tracking Equipment Main Rotor Components
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Tracking Tip Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
D. Main Rotor System Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Main Rotor Balancing Equipment Installation . . . . . . . . . . . . . . . . . . 404
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Blade Tracking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Typical Track Conditions and Adjustments . . . . . . . . . . . . . . . . . . . . . 501
A. Blade Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
B. Pitch Control Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
C. Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Figure 502. Adjustment Main Rotor Blade Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
D. Main Rotor Ground Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
E. Hover Track Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
F. Forward Flight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
2. Main Rotor System Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
3. Main Rotor Autorotation Percentage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Table 501. Summary Procedure for Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . 506
Table 502. Autorotation Percentage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Figure 503. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Figure 504. Main Rotor Track at Hover (Pitch Change Link Adjustment) . . . . . 508
Figure 505. Main Rotor System Balance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Figure 506. Main Rotor Tracking at 100 130 KIAS
(Inner Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
(Mid Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
(Outer Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
182000 Tail Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

A. Balance at Blade Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Balance at Blade Pitch Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Short Method Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Long Method Balance Check (FourBladed Tail Rotor) . . . . . . . . . . . . . . . . . . . . . . 202
2. Horizontal Stabilizer Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Tail Rotor Assembly Balancing (TwoBladed Tail Rotor) . . . . . . . . . 204
Table 201. Tail Rotor Balance Weight Value Chart . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Short Method Tail Rotor Balancing (FourBladed Tail Rotor) . . . . . 205
Figure 203. Long Method Tail Rotor Balancing (Inboard Blade) . . . . . . . . . . . . . . 206
Figure 204. Long Method Tail Rotor Balancing (Outboard Blade) . . . . . . . . . . . . 206
182030 NOTAR) AntiTorque System Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fan Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fan Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Preferred Hardware for Balancing Fan Assembly . . . . . . . . . . . . . . . . 202
Figure 201. Fan Balancing Stud Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fan Balance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Fan Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . 205
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MAINTENANCE MANUAL
Section
181000
Main Rotor Track
and Balance
MAINTENANCE MANUAL
MAIN ROTOR TRACK AND BALANCE

1. Main Rotor Blade Tracking (e). Forward flight tracking (Ref. For-
ward Flight Tracking).
Main rotor blade track is observed by means of
reflective tip caps temporarily installed on (f). Autorotation rpm adjustment (Ref.
each blade and a highintensity strobe light. Main Rotor Autorotation RPM
Blade track is determined by observing the Check).
apparent tip cap pattern created by strobe (2). No attempt should be made to verify or
light pulses synchronized with the rotating adjust blade track without first check-
blades. Strobe light electrical power is supplied ing and adjusting blade phasing, a
by the helicopter electrical system. function of main rotor damper adjust-
ment (Ref. Sec. 622000).
Immediately investigate the
WARNING cause of a sudden onset of CAUTION
Understand the blade tracking
excessive or unusual main rotor vibra- sequence and related adjust-
tion prior to continued flight. Under no ments before attempting blade track proce-
circumstance should main rotor track- dures.
ing be attempted to correct the prob- If main rotor hub balance is suspect, balance ro-
lem until a thorough inspection of the tor hub prior to performing blade track.
main rotor blades, hub assembly and A. Main Rotor Hub Balancing
strap pack assembly has been per-
formed. Main rotor hub balancing is accomplished by
adding or removing weight (flat washers) as
When working near engine air required at the leadlag bolts (Ref. Main Rotor
CAUTION inlet, comply with all precau- Hub Balancing Procedure). Analysis of main
tions to prevent entry of foreign material. rotor hub balance is accomplished using
Carefully observe precautions in the Track- instrumentation that measures and localizes
ing and Balancing Manual relating to the vibrations due to main rotor hub imbalance.
placement and security of equipment (espe- Data provided by the instrumentation is
cially cables) fastened to the exterior of the plotted on a chart designed to indicate how
helicopter. much weight must be added or removed from
the leadlag bolt. No other means of balancing
NOTE: Refer to Table 201 to isolate ground or is to be used.
inflight blade tracking problems. B. Main Rotor System Balancing
(1). Tracking must be accomplished in the Main rotor system balancing is accomplished
following sequence of six steps: by adjusting the turnbuckle on the elastomeric
damper. Analysis of main rotor system balance
(a). Verification of proper blade phasing is accomplished using instrumentation that
(Ref. Main Rotor Blade Phasing measures and localizes vibrations due to main
Check and/or Adjustment, Sec. rotor imbalance (Ref. Main Rotor System
622000). Balance Procedure). Data provided by the
instrumentation is plotted on a chart designed
(b). Ground tracking (Ref. Main Rotor to indicate how much rotor blade shall be
Ground Tracking). shifted in leading or lagging direction by
adjusting turnbuckle. No other means of
(c). Verification of proper rotor balance balancing is to be used. Never add weight to,
(Ref. Main Rotor System Balance subtract weight from or redistribute weight on
Procedure). the main rotor blades. Do not attempt the
blade balancing procedure without first
(d). Hover verification (Ref. Hover Track tracking the blades (Ref. Blade Tracking
Verification). Procedure).
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181000 Revision 23
MAINTENANCE MANUAL
C. Balancing Equipment and Balance Spare

Kit
The balancing equipment contains all equip-
ment needed to analyze main rotor balance.
Table 201. Isolating Tracking Problems
Symptom Probable Cause Corrective Action
GROUND TRACKING
Rotor does not follow adjustments. Turning turnbuckle wrong direction. Adjust correctly.
Pitch link bearing worn. Trim tab Replace bearing. Zero trim tabs.
bent excessively.
Excessive diving or climbing of Trim tab bent excessively. Zero trim tabs.
blade from low speed ground track
to high speed ground track. Pitch link control not coordinated Set pitch link to 6.25 in. (15.875 cm)
with trim tab bend (Intermixing nominal and zero trim tabs.
control input).
Damage to blade or tabs. Inspect for damage.
Excessive torque and erratic high Pitch change links too long. Set to nominal 6.25 in. (15.875 cm).
speed ground tracking.
INFLIGHT TRACKING
Blade track changes with power Worn pitch bearing housing Replace bearings.
and control changes. bearings.
Missing pitch bearing liner. Replace bearing.
Broken or loose feathering studs. Repair or replace studs.
Binding rotating scissor crank at Repair or replace crank.

lower main rotor hub shoe.
Play between longitudinal pitch Rebond collective pitch mixer

mixer bellcrank and collective pitch bearings and install shims between
mixer bellcrank. longitudinal pitch mixer bellcrank and
collective pitch mixer bellcrank
bearings (Ref. Sec. 623000).
Helicopter has rough feeling with Tilted tracking images, no blade in Retrack blades.
some vibration while appearing to track.
be in track.
Pitch link control not coordinated Set pitch link to nominal 6.25 in.
with trim tab bend (intermixing (15.875 cm) and zero trim tabs.
control input), with climbing or
diving blades within acceptable
track limits.
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Revision 31 181000
MAINTENANCE MANUAL
Table 201. Isolating Tracking Problems (Cont.)

Blades very erratic in response to Tab bent too much in wrong area. Correct by limiting bending.
tab bends.
Blade erosion, but within chordwise Track erratic blade to other blades.
limits.
Tab bent too many degrees in one Limit tab bending to smaller degree
area. over larger area.
Blades climb or dive excessively at Too much tab bending in outboard Remove outboard bending and
high speeds. tab areas. increase inboard bending.
Ground track off at low speed and Excessive tab bending and pitch Zero trim tabs and set pitch links to
stick shake at 103% N2. link control not coordinated with tab nominal 6.25 in. (15.875 cm)
bend (intermixing control input).
Helicopter in track but has stick Blade out of phase. Check phasing.
shake.
Feedback in collective control. Main rotor hub out of balance. Balance hub.
Loose or binding rotating scissors. Check and repair as required.
Heavy collective stick climb and Overcenter adjustment set too low. Adjust.
cruise.
Trim tab bent down excessively. Adjust.
Light collective stick climb and Overcenter adjustment set too Adjust.
cruise. high.
Trim tabs bent up excessively. Adjust.
Heavy collective lift-off light flight. Bungee spring adjusted too short. Adjust to nominal.
Light collective lift-off heavy flight. Bungee spring adjusted too long. Adjust to nominal.
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MAINTENANCE MANUAL
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Revision 37 181000
MAINTENANCE MANUAL

REMOVAL/INSTALLATION
1. Main Rotor System Tracking Equipment A. Interrupter Installation
Installation
(Ref. Figure 401)
(Ref. Figure 401 and Figure 402) Equipment (1). The helicopter is equipped with five
needed to track main rotor blades consists of main rotor blade tracking interrupters
the main rotor tracking and tail rotor vibration located immediately inboard of each
analyzer equipment, tracking and balancing pitch control link attach clevis on the
equipment and the tip cap assembly. Instruc- rotating swashplate.
tions for equipment installation are contained
in ChadwickHelmuth Operation and Service (2). The interrupter installation incorpo-
Instruction Handbook. rates a double interrupter which may
be used for both tracking and balanc-
ing.
When working near engine air
CAUTION inlet, comply with precautions
(3). Each interrupter insert is attached to
to prevent entry of foreign material. During
the interrupter body at a different
main rotor balancing the helicopter will be
position (left, center, or right). The
airborne. Carefully observe precautions in
interrupters create five equally spaced
the Tracking and Balancing Manual relat-
horizontal reflective images, as viewed
ing to the placement and security of equip-
by the technician, when the main rotor
ment (especially cables) fastened to the ex-
blade tips are illuminated with the test
terior of the helicopter.
strobe light.
NOTE: Main rotor tracking tip caps manufac- (4). Interrupter blade spacing separates the
tured by the same firm that manufactures image of each main rotor blade tip cap
the tracking and balance equipment, are by approximately 0.25 inch (6.35 mm).
components of the tracking and balancing This staggered relationship allows the
equipment and may be used instead of tip technician to view the stopped image of
cap assembly. In procedures that follow, use each blade in order of rotation.
of tip cap assembly is presumed. If tip caps
from the balancing equipment are used, re- (5). The number one blade is seen on the
fer to the Tracking and Balancing Manual extreme left, number two blade is seen
for tip cap data. second from left, and so on through
number five which is seen on the
extreme right.
Special Tools
(6). On current configuration helicopters,
Item Nomenclature
the pulse of the double interrupter is so
short that it appears as a single pulse
ST901 Tip cap assembly to the strobe light amplifier. The second
pulse created by the double interrupter
ST903 Balancer/analyzer instrument kit
is used during main rotor balancing.
Consumable Materials (7). If counterweights are installed, coat the

(Ref. Section 910000) two interrupter bolts passing through
Item Nomenclature the swashplate counterweights with
grease (CM116) before installation.
CM116 Grease, aircraft and instrument Torque bolts to 30 60 inchpounds
(3.39 6.78 Nm).
Page 401
181000 Revision 23
MAINTENANCE MANUAL
(8). Torque the three remaining interrupter (6). Ensure the interrupter passing closest
bolts to 30 60 inchpounds (3.39 over either early or current configura-
6.78 Nm). tion magnetic pickup, clears pickup by
not less than 0.030 inch (0.762 mm).
B. Magnetic Pickup Installation
C. Tracking Tip Cap Installation
(Ref. Figure 401)
(1). The helicopter is originally equipped (Ref. Figure 401)
with a magnetic pickup support bracket
installed with shim washers to prevent (1). The helicopter is originally equipped
distortion of the bracket when the nut with five tip caps that must be removed
on the bolt that secures the link bearing and replaced with five tracking tip caps
is torqued to 30 60 inchpounds (ST901).
(3.39 6.78 Nm). (2). When blade tracking has been accom-
(2). To preclude rocking movement of plished or verified, the tracking tip caps
magnetic pickup support bracket when must be removed and original tip caps
installed on stationary swashplate, installed.
check clearance between swashplate
and lower flange of bracket. If gap (3). Torque the screw that secures the tip
exists, tap bent tip of lower flange cap to 15 20 inchpounds (1.69
(typical both sides of bracket) until bent 2.26 Nm).
tip touches swashplate. NOTE: When installing tip cap targets, posi-
(3). Reinstall by forcing bracket until tion double interrupter over magnetic pick-
elongated bracket holes align with hole up. The blade positioned forward is number
in stationary swashplate. 5. By rotating rotor head in operating direc-
tion, the next blade pointing forward will be
(4). Install the magnetic pickup and cable 4, then 3, 2 and 1.
as instructed in the ChadwickHel-
muth Operation and Service Instruc- D. Main Rotor System Balancing Equipment
tion Handbook. Installation
(5). After final adjustment, torque the (Ref. Figure 401 and Figure 402) and Chad-
adjustment nut to 15 20 inch wickHelmuth Operation and Service Instruc-
pounds (1.69 2.26 Nm) and ensure tion Handbook to install that portion of the
the cable is routed and tied down in balancing equipment (ST903) needed to
such a manner as not to be dislodged or balance the main rotor.
interfere with control components at
their extremes of travel.
Page 402
Revision 23 181000
MAINTENANCE MANUAL
1
ROTATION PLACE DOUBLE INTERRUPTER TAPE
OVER MAGNETIC PICKUP AND
2 THEN ATTACH TIP TARGET
NUMBERS EXACTLY AS SHOWN
TRACKING TARGET
(NOTE 1)
TIP CAP
TRACKING TIP CAP INSTALLATION INTERRUPTER

ROTATION
(NOTE 4) DOUBLE
OF HUB
INTERRUPTER SCISSORS
SUPPORT NOTE 2
(NOTE 4) LINK
BRACKET
ADJUSTMENT
JAMNUT
ROTATING
SWASHPLATE
TEST EQUIPMENT
PROTECTIVE CAP
CABLE RECEPTACLE
PICKUP INSTALLATION (ROTATED)

INTERRUPTER
(NOTE 4) INTERRUPTER
SPACER (NOTE 4)
INTERRUPTER
(NOTE 3) STATIONARY INTERRUPTER
SWASHPLATE (NOTE 4)
NOTES:
0.0300.070 IN. 1. ALWAYS REMOVE TARGETS
(0.7621.778 MM) AFTER TRACKING.
GAP TYP. 2. INSTALL WASHERS BETWEEN
BRACKET AND SWASHPLATE
TO FILL GAP.
3. ADJUST AS REQUIRED FOR
GAP INDICATED.
INTERRUPTERTOMAGNETIC PICKUP GAP MAGNETIC PICKUP 4. REFER TO CSPIPC4 FOR
PART NO.
G181000B
Figure 401. Blade Tracking Equipment
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181000 Revision 23
MAINTENANCE MANUAL
TAPE CABLE TO RIGHT HAND INBOARD

SIDE OF INLET HOUSING AND ROUTE
MAGNETIC PICKUP CABLE AND
FORWARD ALONG FUSELAGE AS
VELOMETER/ACCELEROMETER VELOMETER/ACCELEROMETER
SHOWN. CABLE MUST CLEAR AL
LOCATION FOR MAIN ROTOR CABLE MAY BE ROUTED
EXTREME MOVEMENTS OF CONTROLS.
BALANCING THROUGH VENT DOOR
KIT LOCATION
FOR MAIN ROTOR
BALANCING
INTERRUPTER
(TYP)
TORQUE NUT AFTER

SECURING GAP AND
SAFETY WIRE
0.0300.070 IN.
(0.7621.778 MM)
GAP (TYP)
ENGINE AIR INLET FAIRING MAGNETIC PICKUP
(LEFT HAND SIDE) VIEW LOOKING DOWN
MAGNETIC PICKUP INSTALLATION
TAPE
VELOMETER/ACCELEROMETER VIEW LOOKING INBOARD

LOCATION FOR MAIN ROTOR
BALANCING
ACCELEROMETER INSTALLATION
G182005
Figure 402. Main Rotor Balancing Equipment Installation
Page 404
Revision 23 181000
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Blade Tracking Procedure
Table 501 is a summary of the sequence of TIP PATH PLANE
required procedures for blade tracking.
1 2 3 4 5
(1). Install strobe light, blade tip cap
IMAGE A: ALL BLADES
reflectors and related equipment. IN TRACK
(2). Use 1/2 inch (12.7 mm) diameter

2
tracking tip cap reflector as a guide for 1 3 4 5
estimating track accuracy. For example: IMAGE B: ONE BLADE APPROX. 1/2 IN. (12.7
MM) HIGH
(a). A tip cap reflector image displace-
ment of 1/2 diameter up, or down, 2
indicates blade tip is approximately 1 4 5
1/4 inch (6.35 mm) out of track. 3
IMAGE C: ONE BLADE APPROX. 1/2 IN. (12.7

(b). One full reflector diameter indicates MM) HIGH
1/2 inch (12.7 mm) out of track. ONE BLADE APPROX. 1 IN. (25.4 G181001A
MM) LOW
CORRECTIVE ACTION
NOTE: Rocking or stick shake caused by a cor-
HIGH RPM AND
rectly tracking rotor indicates improper CONDITION GROUND IDLE RPM FWD FLIGHT
blade phasing.
IMAGE A NONE REQUIRED NONE REQUIRED
(3). Accomplish blade phasing (Ref. Sec. IMAGE B SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
ROD (2ND BLADE) (2ND BLADE) MOVE TAB
622000) when installing new rotor UPWARD (3RD BLADE)
blades or if ground rock or stick shake
IMAGE C SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
is noted. This must be accomplished ROD (2ND BLADE): (2ND BLADE): MOVE TAB
prior to starting tracking procedure. LENGTHEN CONTROL ROD UPWARD (3RD BLADE)
(3RD BLADE)
NOTE: Final rotor system balance cannot be
accomplished until blades are in track. NOTE: Chordwise spacing of tracking images
are not an accurate indication of blade
(4). Ground tracking is basically trackob- phasing. Do not adjust blade phasing in an
servation and adjustment of idle and attempt to equalize spacing. Slight tilting of
flight rpm. Improper track at idle rpm magnetic interrupters or balance of the main
is corrected by adjusting length of pitch rotor system can move the image
control links connecting rotating
swashplate and blade pitch housing. Figure 501. Typical Track Conditions and
Ground track at flat pitch and flight Adjustments
rpm is corrected by blade tab adjust- (6). Forward flight track is corrected only
ment. by making blade tab adjustments.
(5). Hover track verification is essentially Forward flight tracking requires track
an observation to check for track observation during following airspeeds
variations between high rpm (flat pitch) and maneuvers: Flight at 0100 knots.
ground track check and hovering. Fortyfive degree banked turns at
80100 knots. Flight at 100155 knots.
NOTE: Track adjustments are not made on ba- (7). Check for proper balance of rotor
sis of track observations during hovering. system prior to checking autorotation.
However, track variations should be noted
and recorded for use during check of track in (8). Obtaining correct autorotation rpm
forward flight. consists of checking main rotor rpm
Page 501
181000 Revision 23
MAINTENANCE MANUAL
during stabilized autorotation flight

and adjusting rpm to specified limits as Special Tools
necessary. Autorotation rpm check (Ref. Section 910000)
must be accomplished to ensure that Item Nomenclature
track adjustments do not alter rotor ST902 Main rotor blade fixture and tab bending
performance necessary for safe power tool
off landings.
A. Blade Track Adjustment Minimize bending and restrict
CAUTION adjustments to very small incre-
Although adjustment of pitch control links
ments so that bonded trailing edge joint be-
affects blade track at all rotor speeds, they
tween upper and lower skins is not dam-
should be adjusted only when necessary to
aged. Tabs must never be displaced more
establish acceptable track at ground idle
than five degrees above or below neutral po-
speed; blade tabs are used for all other track
sition (parallel to chordline).
corrections.
(1). To lower blade tip that tends to climb
NOTE: Blade tab and/or track can make the during ground tracking at high rpm or
collective heavy or light. during forward flight, bend appropriate
B. Pitch Control Link Adjustment tab section slightly downward; to raise
tip of blade that tends to descend, bend
Repeat this adjustment procedure as necessary tab slightly upward. If only slight track
to establish ground idle track: correction is necessary, limit tab
bending to width of bending tool. If
(1). To lower a blade tip, shorten pitch more correction is necessary, bend a
control link assembly. To raise a blade slightly wider section of tab. Use small
tip, lengthen pitch control link assem- adjustments to avoid excessive rebend-
bly. Onesixth of a turn of link (one flat) ing of tabs.
raises or lowers blade tip approximately
1/4 inch (6.35 mm). NOTE: Tab zones on same blade can require
bending in opposite directions. For example,
Center each rod end or (fitting
CAUTION wear) results. Make sure there after bending tab zone A downward to get
good tracking at 6090 knots, it might be-
is no binding in full up travel position. come necessary to bend tab zone D or E up-
(2). After adjusting pitch control link ward to correct track at redline airspeed. In
length, center each rod end in its fitting any case, do not use larger tab corrections
and hold while tightening jam nuts; than are actually necessary.
safety with lockwire. (2). Each time blade tabs are adjusted,
C. Blade Tab Adjustment recheck ground idle track and readjust
if necessary.
(Ref. Figure 502) Once ground idle track is
obtained, all remaining tracking correction is (3). After completion of forward flight
accomplished by very slight bending of various tracking, balance and check autorota-
blade tab zones with tab bending tool (ST902). tion rpm.
Different zones of tabs are used to adjust blade D. Main Rotor Ground Tracking
track at different airspeeds. In general, tab
zone A is used for high rpm, flat pitch ground (Ref. Figure 502) For best results, tracking
tracking (369D/E 103% N2, 369FF/500N should be performed under calm air conditions.
100% N2) and zones C, D, and sometimes E, Wind velocity should not exceed six knots
are used for tracking at higher airspeeds. Zone during adjustments. Accurate adjustment of
B is used to supplement zone A track correc- initial ground track is very important. In most
tion when maximum tab (5 degrees) has been instances, forward flight tracking problems
applied to zone A; if necessary, zone B may can be avoided or greatly reduced by setting
also be used for correction in 0110 knot initial track as nearly perfect as possible.
airspeed range. Tolerances specified in following instructions
Page 502
Revision 34 181000
MAINTENANCE MANUAL
should be considered maximum permissible blade tab zone A until high rpm ground
deviation rather than desired goal. track is within tolerance.
NOTE: If main rotor hub or a pitch control rod E. Hover Track Verification
end bearing has been replaced, adjust pitch
control link(s) before proceeding with (Ref. Figure 502)
ground tracking.
(1). Hover track verification must be
performed after ground tracking and
(1). Before tracking blades that are not new, before forward flight tracking. Verifica-
check that normally straight (not to be tion is only a check of hover track. Do
used) tab areas are in neutral position not adjust pitch control links or blade
(centered on chordline) and straight. tabs because of track images observed
during hovering. Tab adjustments often
NOTE: On new (untracked) blades, check that cause variation between ground track
all tab areas are straight and in neutral po- and hovering track. A large track
sition (centered on chordline 0 0.5). variation may indicate that one or more
blades is beyond its chordwise balance
tolerance, but this can only be deter-
(2). Load helicopter to a gross weight of mined during forward flight tracking.
approximately 2350 pounds (1066 kg); Perform hover track verification as
then ground idle (approximately follows.
6465% N1).
NOTE: Collective pitch stick may be "heavy" af-
(3). Observe tracking tip cap reflector image ter tracking reflectors are mounted on blade
by directing strobe light beam toward tips. This condition is not unusual and may
blade tip path and sweeping beam be disregarded.
slowly back and forth until reflector
images are clearly seen. Tracking image (2). Verify helicopter gross weight of
should appear directly in front of 20002500 pounds (9081135 kg).
helicopter or slightly off helicopter
centerline. (3). With collective pitch stick full down,
increase N2 to 103% 369D/E, 100%
(4). If blades are in track, tip cap reflector 369FF/500N.
image pattern should resemble image A
(Ref. Figure 501), (no blade tip more (4). Observe tracking reflector images to
than 1/4 of one tracking reflector verify that ground track is within
diameter, 1/8 inch (3.175 mm) above or limits.
below adjacent reflectors). If blades are
in track, proceed with (5). below. If (5). With helicopter in a stable hover,
blades are out of track, adjust pitch observe reflector images. If one or more
control links and repeat step (3). above. blades are out of track, record condi-
tion(s) for reference during forward
(5). With collective pitch stick full down, flight tracking.
increase engine speed to 103% N2
369D/E, 100% N2 369FF/500N and (6). Proceed with forward flight tracking.
observe tip cap reflector image to see if
blade track is changed from ground idle Use of the tracking strobe
track. When all five blades are in track WARNING light in night flight is not
within 1/4 of one reflector diameter, 1/8 recommended. Such use can result in
inch (3.175 mm), ground track is pilot disorientation or loss of vision
correct; proceed with hover verification. with resultant damage to the helicop-
When a blade is out of track, adjust ter and personal injury.
Page 503
181000 Revision 23
MAINTENANCE MANUAL
BLADE STATIONS 93 99 105 111 117 124 130 142 158

MAIN ROTOR BLADE
(TOP VIEW)
65 IN.
(165 CM) 59 IN.
(150 CM) 53 IN.
369D/E (135 CM) 47 IN.
(119 CM) 41 IN.
(104 CM) 34 IN.
(86 CM) 28 IN.
(71 CM) 16 IN.
(41 CM)
TAB ZONES E D A
NOT USED
(NOTE 1) C B TO END OF
NOTE 2 BLADE NOT USED
HIGH RPM GROUND (NOTE 1)
MEDIUM SPEED
TRACKING AND UP TO
FLIGHT TRACKING
110 KNOTS IN FLIGHT
130145 KNOTS
(103 % N2)
HIGH SPEED 110130 KNOTS
FLIGHT TRACKING IN FLIGHT
130145 KNOTS (103 % N2)
(103 % N2)
MAIN ROTOR BLADE BLADE STATIONS 93 99 105 111 117 124 130 148 164
(TOP VIEW)
71 IN.
(180 CM) 65 IN.
(165 CM) 59 IN.
369FF/500N (150 CM) 53 IN.
(135 CM) 47 IN.
(119 CM) 40 IN.
(102 CM 34 IN.
(86 CM) 16 IN.
(41 CM)
TAB ZONES E D A
NOT USED
(NOTE 1) C B TO END OF
NOTE 2 BLADE NOT USED
HIGH RPM GROUND (NOTE 1)
MEDIUM SPEED TRACKING AND UP TO
FLIGHT TRACKING 110 KNOTS IN FLIGHT
130145 KNOTS
SHOCK CORD (100% N2) 110130 KNOTS
(OR EQUIVALENT) HIGH SPEED IN FLIGHT
FLIGHT TRACKING (100% N2)
145152 KNOTS
(100% N2)
NOTES:
1. UNUSED TAB ZONES MUST BE MAINTAINED
STRAIGHT, NEUTRAL AND PARALLEL.
2. USE ONLY AS NECESSARY TO SUPPLEMENT
ZONE D TO AVOID EXCESSIVE TAB BENDING
POINTER IN ZONE D.
TAB BENDING TOOLS
BENDER
G181002C
Figure 502. Main Rotor Blade Tab Adjustment
Page 504
Revision 23 181000
MAINTENANCE MANUAL
F. Forward Flight Tracking NOTE: When determining whether blade track

is acceptable, overall vibration level of heli-
copter should be determining factor. Some
(Ref. Figure 502) Forward flight tracking combinations of rotor blades might produce
should be performed whenever vertical flight higher fiveperrevolution vibration as
vibrations indicate that blades may be out of blade tips are brought into close track; in
track. such cases, lowest vibration level is pre-
ferred, even though observed blade track
(1). Verify helicopter gross weight of may be beyond specified tolerances.
20002500 pounds (9071134 kg). (4). After flight tracking is completed,
perform a Main Rotor System Balance
(2). Perform flight tracking from hover up Procedure and Main Rotor Autorotation
to 110 knots at 103% N2 369D/E, RPM Check.
100% N2 369FF/500N. If flight track
3. Main Rotor System Balance Procedure
varies from hover track more than 1/2
inch (12.7 mm), bend tab zone A (five Balance the main rotor system according to
degrees maximum) to limit variation to instructions in the Tracking and Balancing
tab zone B (five degrees maximum). Manual. Since vibration reduction is accom-
plished by slight adjustment in phasing, the
instruction outline in the Tracking and
2. Main Rotor Blade Tab Adjustment Balancing Manual must be closely followed for
best results. Safety damper turnbuckle after
completing phasing balance adjustments.
(1). Check autorotation rpm; rpm must not
be less than 480. 4. Main Rotor Autorotation RPM Check
(Ref. Table 502 for 369D/E and Table 503
Do not attempt to adjust chord- 369FF and 500N). An autorotation rpm check
CAUTION wise balance of a blade found to
is required after each blade tracking operation
be faulty when performing banked turns. and whenever rpm is outside limits listed.
Chordwise balance corrections must be ac- Check rotor rpm and make adjustments as
complished by manufacturer (MDHI). follows.
(2). Perform a series of 45 degree banked CAUTION

turns at 100 knots and observe track
change from level flight. If any blade D All autorotation rpm adjustments shall
climbs or dives more than one inch out be made at the main rotor pitch control
of track with others, chordwise balance links only. Do not readjust mixer control
(center of gravity) of that blade is rods after rigging is accomplished. Fail-
beyond its tolerance and blade must be ure to observe this precaution may result
replaced. (Hover track variations of this in serious damage to rotor system and
type that do not repeat during banked controls. Do not adjust control rod end be-
turn maneuver may be disregarded.) yond witness hole.
D Tracking targets reduce blade to tailboom
clearance, performing autorotations to
(3). Perform flight tracking at 110155 the ground could result in boom strikes.
knots and 103% N2 369D/E, 100% N2
369FF/500N. If necessary, adjust tab NOTE: Change length of all five pitch control
zone B (five degrees maximum) to limit links as necessary to adjust autorotation
track variation to 1/2 inch (12.7 mm) or rpm. Be sure to lengthen or shorten all five
less and to minimize excessive vertical links exactly same amount or blade track is
(oneper revolution) vibration. If changed. One flat (1/6 turn) of control link
variation is excessive, bend tab zone C body causes approximately four rpm change
or D (five degrees maximum). in autorotation rpm.
Page 505
181000 Revision 23
MAINTENANCE MANUAL
(1). Autorotation Rpm Check: Load 369D/E

helicopter to a gross weight of 2250 Consumable Materials
pounds (1021 kg): 2350 pounds (1066 (Ref. Section 910000)
kg) for 369FF and 500N. Perform a Item Nomenclature
practice autorotative descent (Ref. CM420 Sealant
PFM), taking care not to allow rpm to
exceed rotor speed limitations. During Special Tools
autorotation take careful note of (Ref. Section 910000)
stabilized autorotation rpm at one of Item Nomenclature
gross weight/density altitude combina- ST903 Balancer/analyzer instrument kit
tions. After landing, compare observed
rpm with values (Ref. Tables 502 and
503). If observed rpm is within limits in NOTE:
table, rpm setting is correct. If limits D If swashplate has weights removed, there
were exceeded, make corrective adjust- should be three AN9703 washers at the
ments according to (2). below, until rpm green pitch housing bolt.
is within limits. D In some instances, main rotor hub bal-
ance may not be achieved without addi-
tion of swashplate weights (Ref. Sec.
NOTE: After autorotation rpm adjustments are 623000, Counterweight and
satisfactorily accomplished, remove track- Interrupter Installation)
ing equipment before returning helicopter
to service. Be sure to correctly tighten and (1). Remove main rotor blades.
safety all bolts after they are reinstalled. (2). Remove main rotor dampers.
(3). Hook up Phazor. Refer to Chadwick
(2). Autorotation Rpm Adjustment: Change Helmuth Operation and Service
length of all five pitch control links as Instruction Handbook (ST903).
required to adjust autorotation rpm.
Make certain all five links are short- (4). Run engine at 103% N2 369D/E, 100
N2 369FF/500N.
ened or lengthened exactly the same
amount or blade track will be altered. (5). Record IPS reading and direction on
main rotor balance chart (Ref.
Figure 503).
CAUTION (6). Plot IPS reading and direction on main
rotor balance chart (Ref. Figure 503).
D Do not adjust (lengthen) pitch control link (7). Analyze chart for weight location and
rodend threads beyond witness holes in amount requirements.
rods.
The maximum allowable bal-
CAUTION
D Do not readjust mixer control rods after ance weight per leadlag bolt on
rigging has once been accomplished. Fail- the main rotor hub assembly is 150 grams.
ure to observe this precaution can result (8). Install weights as follows: (Ref.
in serious damage to rotor system and Figure 504).
controls.
(a). Engage head of screw, inside leadlag
bolt, with Phillips screwdriver, then
loosen locknut with 1/4 inch wrench.
5. Main Rotor Hub Balancing Procedure
(b). Hold screw in place with screwdriver
while adding or removing flat wash-
Balance the main rotor hub according to the ers as required, then reinstall
following instructions. locknut.
Page 506
Revision 24 181000
MAINTENANCE MANUAL
(9). Repeat steps (4). thru (8). until reading (11). Reinstall main rotor blades (Ref. Sec.
is 0.15 IPS, or less. 621000).
(10). After balance has been established NOTE: If main rotor dampers require more
satisfactorily, torque MS21042L08 than four flats adjustment, rephase main
locknuts to 20 35 inchpounds (2.26 rotor dampers (Ref. 622000, Main Rotor
3.95 Nm) or MS21042L3 locknuts to Damper Phasing Procedure).
30 60 inchpounds (3.39 6.78 Nm)
as applicable. Coat screw threads, nuts (12). Perform main rotor system balance.
and washers with sealant (CM420). (To
prevent imbalance, do not use excessive (13). Track main rotor blades (Ref. Blade
amount of sealant.) Tracking Procedure).
NOTE: Intermixing of P/N 369D21400503 and
M50452 main rotor blade damper assem-
blies in a shipset is not permitted. All damp-
ers in shipset must be of same type and part
number.
Table 501. Summary Procedure for Blade Tracking

Satisfactory Unsatisfactory
Step Result Result Corrective Action
(1) Observe ground track. Go to step (2). Ref. Corrective Adjust pitch control links and blade
Action. tabs as required. Repeat track
observation.
(2) Perform hover verification. Go to step (3). Ref. Corrective Record track verification and proceed
Action. with forward flight tracking.
(3) Perform forward flight tracking. Go to step (4). Ref. Corrective Adjust blade tabs and repeat forward
Action. flight tracking.
(4) Perform autorotation rpm Go to step (5). Ref. Corrective Adjust autorotation rpm and repeat
check. Action. rpm check.
(5) Remove tracking equipment

and return helicopter to service.
NOTE: Ground rock or stick shake with rotor blades in track during ground track indicates rotor blades are not
properly phased.
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181000 Revision 24
MAINTENANCE MANUAL
Table 502. Autorotation Rpm Chart (369D/E)
Gross Wt Stabilized Autorotation Rpm at Density Chart

lb/kg Sea Level 1000 Ft 2000 Ft 3000 Ft 4000 Ft 5000 Ft
2050/930 460 470 466.5 476.5 473 483 479.5 489.5 486 496 492.6 502.6
2150/975 470 480 476.5 486.5 483 493 489.5 499.5 496 506 502.6 512.6
2250/1021 480 490 486.5 496.5 493 503 499.5 509.5 506 516
2350/1066 490 500 496.5 506.5 503 513 509.5 519.5
NOTES:
(1) Chart values based upon 15C (59F) outside air temperature. At sea level, 8C (14F) temperature
change is equal to 1000 feet (305 M) of change in density altitude.
(2) Perform autorotation rpm checks at gross weight/density altitude combinations for which rpm values are
given. Blank spaces indicate that application of collective pitch may be necessary to avoid rotor
overspeed.
Table 503. Autorotation Rpm Chart (369FF/500N)

Gross Wt Stabilized Autorotation Rpm at Density Chart
lb/kg Sea Level 1000 Ft 2000 Ft 3000 Ft 4000 Ft 5000 Ft
2216/1005 459469 465475 471481 477487 483493 489499
2316/1051 466476 472482 478488 484494 490500 496506
2416/1096 473483 479489 485495 491501 497507
2516/1189 480490 486496 492502 498508
NOTES:
(1) Chart values based upon 15C (59F) outside air temperature. At sea level, 8C (14F) temperature
change is equal to 1000 feet (305 M) of change in density altitude.
(2) Perform autorotation rpm checks at gross weight/density altitude combinations for which rpm values are
given. Blank spaces indicate that application of collective pitch may be necessary to avoid rotor
overspeed.
Page 508
Revision 23 181000
MAINTENANCE MANUAL
60 GRAMS
BLUE
4 40
40 YEL
GRN 20
2 3
12
0
40 20 1 20
11
60 GRAMS 1.0
.9
.8
0 TGT
.7
2 WHITE
40 10 .6
20 5
YEL .5
3 .4
.3 40
20
.2
.1 .1 .2 .3 .4 .5 .6 .7 .8 .9 1.0
3 60 GRAMS
9 .1
0
.2
.3 40
.4
.5 BLUE
RED 20 20 4
1 .6
8 4
.7
.8 0
40 .9
1.0
7 5 20
20 0 RED
60 GRAMS 40 6
1
20 40
GRN
2 40
TGT
WHITE 60 GRAMS
HELICOPTER S/N HUB S/N 5
G181003A
CLOCK BALANCE WEIGHT AND LOCATION

RUN NO. IPS
ANGLE (1) RED (2) GREEN (3) YELLOW (4) BLUE (5) WHITE
Figure 503. Main Rotor Hub Balancing Chart
Page 509
181000 Revision 23
MAINTENANCE MANUAL
MS21042L08 NUT A
369D29935 MAIN ROTOR NOTE 1 (NOTE 2)
HUB BALANCE WEIGHT AN960C8, AN960C8L WASHERS
SUPPORT WASHER AS REQUIRED TO BALANCE
(NOTE 5)
369D21220 LEADLAG BOLT
369D29934 WASHER
NAS60264P, 72P OR 76P

SCREW
369D21300501
LINK ASSY PITCH HOUSING
369A1219 NUT AND
MS24665300 COTTER PIN
(NOTE 4)
AA
SERIAL NO. 0260D AND SUBS
MS21042L3 LOCKNUT
(NOTE 3)
NOTE 1 AN960C10, AN960C10L WASHERS
AS REQUIRED TO BALANCE
(NOTE 5)
HS1555 WASHER AN9703 WASHER
369A1220 LEADLAG BOLT
HS1554 WASHER
369A1219 NUT AND NAS60356 OR 64

MS24665300 COTTER PIN SCREW
(NOTE 4)
AA
SERIAL NO. 003D THRU 0259D
NOTES:
1. COAT SCREW THREADS, NUTS AND WASHERS
WITH PR1436G, CLASS B2 SEALANT.
2. TORQUE MS21042L08 NUT TO 20 35 INCHPOUNDS
(2.26 3.95 NM).
3. TORQUE MS21042L3 NUT TO 30 60 INCHPOUNDS
(3.39 6.78 NM).
4. DO NOT REMOVE OR DISTURB TORQUE ON 369A1219 NUT. G181004B
5. THE MAXIMUM ALLOWABLE BALANCE WEIGHT PER LEADLAG
BOLT ON THE MAIN ROTOR HUB ASSEMBLY IS 150 GRAMS.
Figure 504. Main Rotor Hub Balancing
Page 510
Revision 39 181000
MAINTENANCE MANUAL
Section
181060
Main Rotor Track
and Balance (600N)
MAINTENANCE MANUAL
MAIN ROTOR TRACK AND BALANCE (600N)

1. Main Rotor Blade Tracking
CAUTION
Immediately investigate the D Understand the blade tracking sequence
WARNING cause of a sudden onset of and related adjustments before attempt-
excessive or unusual main rotor vibra- ing blade track procedures.
tion prior to continued flight. Under no D If main rotor hub balance is suspect, bal-
circumstance should main rotor track- ance rotor hub prior to performing blade
ing be attempted to correct the prob- track.
lem until a thorough inspection of the
main rotor blades, hub assembly and 2. Main Rotor System Balancing
strap pack assembly has been per-
formed. Main rotor hub balancing is accomplished by
adding or removing weight (flat washers) as
NOTE: Ref. Table 201 to isolate ground or in required at the leadlag bolts (Ref. Main Rotor
flight blade tracking problems. Hub Balancing Procedure). Analysis of main
rotor hub balance is accomplished using
instrumentation that measures and localizes
Main rotor blade track is observed by means of vibrations due to main rotor hub imbalance.
reflective tip caps temporarily installed on Data provided by the instrumentation is
each blade and a highintensity strobe light. plotted on a chart designed to indicate how
Blade track is determined by observing the much weight must be added or removed from
apparent tip cap pattern created by strobe the leadlag bolt. No other means of balancing
light pulses synchronized with the rotating is to be used.
blades. Strobe light electrical power is supplied
by the helicopter electrical system. 3. Balancing Equipment and Balance Spare
Kit
a. Tracking must be accomplished in the follow-
ing sequence of six steps:
Special Tools
1). Verification of proper blade phasing
(Ref. Main Rotor System Balance Procedure).
Item Nomenclature
2). Ground tracking
(Ref. Main Rotor Ground Tracking). ST903 Balancer/analyzer instrument kit
3). Verification of proper rotor balance
(Ref. Main Rotor System Balance Procedure). The balancing equipment (ST903) contains all
4). Hover verification equipment needed to analyze main rotor
(Ref. Hover Track Verification). balance.
5). Forward flight tracking
(Ref. Forward Flight Tracking). CAUTION inlet, comply with all precau-
6). Autorotation rpm adjustment tions to prevent entry of foreign material.
(Ref. Main Rotor Autorotation RPM Check). Carefully observe precautions in the Track-
b. No attempt should be made to verify or adjust ing and Balancing Manual relating to the
blade track without first checking and adjust- placement and security of equipment (espe-
ing blade phasing, a function of main rotor cially cables) fastened to the exterior of the
damper adjustment. helicopter.
Page 201
181060 Revision 23
MAINTENANCE MANUAL
Table 201. Isolating Tracking Problems
GROUND TRACKING
Rotor does not follow adjustments. Turning P/C link wrong direction. Adjust correctly.
Pitch link bearing worn. Trim tab Replace bearing. Zero trim tabs.
bent excessively.
Excessive diving or climbing of Trim tab bent excessively. Zero trim tabs.
blade from low speed ground track
to high speed ground track. Pitch link control not coordinated Set pitch link to nominal 6.25 inches
with trim tab bend (Intermixing (15.88 cm) and zero trim tabs.
control input).
Damage to blade or tabs. Inspect for damage.
Excessive torque and erratic high Pitch change links too long or Set to nominal 6.25 inches (15.88
speed ground tracking. collective rigging too high. cm). Check collective rigging.
INFLIGHT TRACKING
Blade track changes with power Worn pitch bearing housing Replace bearings.
and control changes. bearings.
Missing pitch bearing liner. Replace bearing.
Broken or loose feathering studs. Repair or replace studs.
Binding rotating scissor crank at Repair or replace crank.

lower main rotor hub shoe.
Play between longitudinal pitch Rebond collective pitch mixer

mixer bellcrank and collective pitch bearings and install shims between
mixer bellcrank. longitudinal pitch mixer bellcrank and
bearings (Ref. Sec. 623060).
Helicopter has rough feeling with Tilted tracking images, no blade in Retrack blades.
some vibration while appearing to track.
be in track.
Pitch link control not coordinated Set pitch link to nominal 6.25 inches
with trim tab bend (intermixing (15.88 cm) and zero trim tabs.
control input), with climbing or
diving blades within acceptable
track limits.
Blades very erratic in response to Tab bent too much in wrong area. Correct by limiting bending.
tab bends.
Blade erosion, but within chordwise Track erratic blade to other blades.
limits.
Tab bent too many degrees in one Limit tab bending to smaller degree
area. over larger area.
Blades climb or dive excessively at Too much tab bending in outboard Remove outboard bending and
high speeds. tab areas. increase inboard bending.
Page 202
Revision 31 181060
MAINTENANCE MANUAL
Table 201. Isolating Tracking Problems (Cont.)

Ground track off at low speed and Excessive tab bending and pitch Set pitch link to nominal 6.25 inches
stick shake at 100% N2. link control not coordinated with tab (15.88 cm) and zero trim tabs.
bend (intermixing control input).
Helicopter in track but has stick Blade out of phase. Check phasing.
shake.
Feedback in collective control. Main rotor system out of balance. Balance rotor system.
Loose or binding rotating scissors. Check and repair as required.
Heavy collective stick climb and Overcenter adjustment set too low. Adjust.
cruise.
Trim tab bent down excessively. Adjust.
Light collective stick climb and Overcenter adjustment set too Adjust.
cruise. high.
Trim tabs bent up excessively. Adjust.
Heavy collective lift-off light flight. Bungee spring adjusted too short. Adjust to nominal.
Light collective lift-off heavy flight. Bungee spring adjusted too long. Adjust to nominal.

181060 Revision 31
MAINTENANCE MANUAL

1. Main Rotor System Tracking Equipment (4). The number one blade is seen on the
Installation extreme left, number two blade is seen
second from left, and so on thru number
(Ref. Figure 401 and Figure 402) Equipment six which is seen on the extreme right.
needed to track main rotor blades consists of
the tracking and balancing equipment (ST903) (5). Additional interrupters can be added to
and the tip cap assemblies (ST901). Instruc- be compatible with the older balance/
tions for equipment installation are contained analyzer instrument kits.
in ChadwickHelmuth Operation and Service
Instruction Handbook. (6). Torque the interrupter bolts to 30 60
inchpounds (3.39 6.78 Nm).
Special Tools B. Magnetic Pickup Installation

(1). The helicopter is originally equipped
Item Nomenclature
with a magnetic pickup support bracket
ST901 Tip cap assembly installed with shim washers to prevent
ST903 Balancer/analyzer instrument kit distortion of the bracket when the nut
on the bolt that secures the link bearing
is torqued to 30 60 inchpounds
(3.39 6.78 Nm).
NOTE: Main rotor tracking tip caps manufac-
tured by the same firm that manufactures (2). To preclude rocking movement of
the tracking and balance equipment, are magnetic pickup support bracket when
components of the tracking and balancing installed on stationary swashplate,
equipment and may be used instead of tip check clearance between swashplate
cap assembly (ST901). In procedures that and lower flange of bracket. If gap
follow, use of tip cap assembly is presumed. exists, tap bent tip of lower flange
If tip caps from the balancing equipment are (typical both sides of bracket) until bent
used, refer to the Tracking and Balancing tip touches swashplate.
Manual for tip cap data.
(3). Reinstall by forcing bracket until
A. Interrupter Installation elongated bracket holes align with hole
in stationary swashplate.
(1). The helicopter is equipped with a main
rotor blade tracking interrupter located (4). Install the magnetic pickup and cable
on the rotating swashplate. as instructed in the ChadwickHel-
muth Operation and Service Instruc-
tion Handbook.
(2). The interrupter creates six equally
spaced horizontal reflective images, as (5). After final adjustment, torque the
viewed by the technician, when the adjustment nut to 15 20 inch
main rotor blade tips are illuminated pounds (1.69 2.26 Nm) and ensure
with the test strobe light. the cable is routed and tied down in
such a manner as not to be dislodged or
(3). The balance analyzer separates the interfere with control components at
image of each main rotor blade tip cap their extremes of travel.
by approximately 0.25 inch (6.35 mm).
This staggered relationship allows the (6). Ensure the interrupter passing closest
technician to view the stopped image of over magnetic pickup, clears pickup by
each blade in order of rotation. not less than 0.030 inch (0.76 mm).
Page 401
181060 Revision 23
MAINTENANCE MANUAL
PLACE DOUBLE INTERRUPTER

ROTATION
OVER MAGNETIC PICKUP AND TAPE
THEN ATTACH TIP TARGET
NUMBERS EXACTLY AS SHOWN.
TRACKING TARGET
(NOTE 1)
SCISSORS
CRANK
TIP CAP
ROTATION
OF HUB
TRACKING TIP CAP
INSTALLATION
INTERUPTER
SCISSORS LINK (NOTE 4)
INTERUPTER
(NOTE 4)
ROTATING
SWASHPLATE
STATIONARY
SWASHPLATE
NOTES:
1. ALWAYS REMOVE TARGETS AFTER TRACKING.
2. INSTALL WASHERS BETWEEN BRACKET AND
SWASHPLATE TO FILL GAP. MAGNETIC PICKUP
3. ADJUST AS REQUIRED FOR GAP INDICATED.
6G180141
4. REFER TO IPC FOR PART NUMBER.
Figure 401. Blade Tracking Equipment Main Rotor Components (Sheet 1 of 2)
Page 402
Revision 23 181060
MAINTENANCE MANUAL
0.0300.070 IN.
(0.7621.778 MM)
GAP (TYP) SUPPORT
INTERRUPTER BRACKET
(NOTE 3)
NOTE 2
JAM NUT
(ADJUSTMENT)
TEST EQUIPMENT
CABLE RECEPTACLE
PROTECTIVE CAP
INTERRUPTERTOMAGNETIC PICKUP GAP
PICKUP INSTALLATION
6G180142
Figure 401. Blade Tracking Equipment Main Rotor Components (Sheet 2 of 2)

C. Tracking Tip Cap Installation D. Main Rotor System Balancing Equipment
Installation
(1). The helicopter is originally equipped
with six tip caps that must be removed
and replaced with six tracking tip caps Refer to ChadwickHelmuth Operation and
(ST901).
Service Instruction Handbook to install that
(2). When blade tracking has been accom- portion of the balancing equipment (ST903)
plished or verified, the tracking tip caps needed to balance the main rotor.
must be removed and original tip caps
installed.
(3). Torque the screws that secures the tip CAUTION inlet, comply with precautions
cap to 15 20 inchpounds (1.69 to prevent entry of foreign material. During
2.26 Nm). main rotor balancing the helicopter will be
NOTE: Position interrupter over magnetic airborne. Carefully observe precautions in
pickup. The blade positioned forward is the Tracking and Balancing Manual relat-
number 6. By rotating rotor head in operating to the placement and security of equip-
ing direction, the next blade pointing for- ment (especially cables) fastened to the ex-
ward will be 5 then 4, 3, 2 and 1. terior of the helicopter.
Page 403
181060 Revision 23
MAINTENANCE MANUAL
INTERRUPTER
(TYP)
TORQUE NUT AFTER

SECURING GAP AND
SAFETY WIRE
VIEW LOOKING DOWN
0.0300.070 IN.
MAGNETIC (0.7621.778 MM)
PICKUP GAP (TYP)
ENGINE AIR INLET FAIRING
(LEFT HAND SIDE)
MAGNETIC PICKUP INSTALLATION
ACCELEROMETER/VELOMETER
LOCATION FOR MAIN ROTOR
BALANCING
VIEW LOOKING
INBOARD
TAPE
ACCELEROMETER INSTALLATION
6G18015
Figure 402. Main Rotor Balancing Equipment Installation
Page 404
Revision 23 181060
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Blade Tracking Procedure
TIP PATH PLANE
Table 501 is a summary of the sequence of
required procedures for blade tracking.
(1). Install strobe light, blade tip cap
IMAGE A: ALL BLADES IN TRACK
reflectors and related equipment.
(2). Use 1/2 inch (12.7 mm) diameter
tracking tip cap reflector as a guide for
estimating track accuracy. For example: IMAGE B: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH
(a). A tip cap reflector image displace-

ment of 1/2 diameter up, or down,
indicates blade tip is approximately
1/4 inch (6.35 mm) out of track.
IMAGE C: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH
(b). One full reflector diameter indicates ONE BLADE APPROX. 1 IN. (25.4 MM) LOW
1/2 inch (12.7 mm) out of track. 6G18016A
CORRECTIVE ACTION
NOTE: Rocking or stick shake caused by a cor-
HIGH RPM AND
rectly tracking rotor indicates improper CONDITION GROUND IDLE RPM FWD FLIGHT
blade phasing.
IMAGE A NONE REQUIRED NONE REQUIRED
(3). Accomplish blade phasing (Ref. Sec. IMAGE B SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
ROD (2ND BLADE) (2ND BLADE) MOVE TAB
622060) when installing new rotor UPWARD (3RD BLADE)
blades or if ground rock or stick shake
IMAGE C SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
is noted. This must be accomplished ROD (2ND BLADE): (2ND BLADE): MOVE TAB
prior to starting tracking procedure. LENGTHEN CONTROL ROD UPWARD (3RD BLADE)
(3RD BLADE)
NOTE: Final rotor system balance cannot be
accomplished until blades are in track. NOTE: Chordwise spacing of tracking images
are not an accurate indication of blade phas-
(4). Ground tracking is basically trackob- ing. Do not adjust blade phasing in an at-
servation and adjustment of idle and tempt to equalize spacing. Slight tilting of
flight rpm. Improper track at idle rpm magnetic interrupters or balance of the
is corrected by adjusting length of pitch main rotor system can move the image
control links connecting rotating
swashplate and blade pitch housing. Figure 501. Typical Track Conditions and
Ground track at flat pitch and flight Adjustments
rpm is corrected by blade tab adjust- (6). Forward flight track is corrected only
ment. by making blade tab adjustments.
(5). Hover track verification is essentially Forward flight tracking requires track
an observation to check for track observation during following airspeeds
variations between high rpm (flat pitch) and maneuvers: Flight at 0100 knots.
ground track check and hovering. Fortyfive degree banked turns at
80100 knots. Flight at 100155 knots.
NOTE: Track adjustments are not made on ba- (7). Check for proper balance of rotor
sis of track observations during hovering. system prior to checking autorotation.
However, track variations should be noted
and recorded for use during check of track in (8). Obtaining correct autorotation rpm
forward flight. consists of checking main rotor rpm
Page 501
181060 Revision 23
MAINTENANCE MANUAL
during stabilized autorotation flight sometimes E, are used for tracking at higher
and adjusting rpm to specified limits as airspeeds. Zone B is used to supplement zone
necessary. Autorotation rpm check A track correction when maximum tab (5
must be accomplished to ensure that degrees) has been applied to zone A; if
track adjustments do not alter rotor necessary, zone B may also be used for
performance necessary for safe power correction in 0110 knot airspeed range.
off landings.
Special Tools
A. Blade Track Adjustment
Although adjustment of pitch control links Item Nomenclature
affects blade track at all rotor speeds, they ST902 Main rotor blade fixture and tab bending
should be adjusted only when necessary to tool
establish acceptable track at ground idle
speed; blade tabs are used for all other track Minimize bending and restrict
corrections. CAUTION adjustments to very small incre-
ments so that bonded trailing edge joint be-
NOTE: Blade tab and/or track can make the tween upper and lower skins is not dam-
collective heavy or light.
aged. Tabs must never be displaced more
B. Pitch Control Link Adjustment than five degrees above or below neutral po-
sition (parallel to chordline).
Repeat this adjustment procedure as necessary
to establish ground idle track: (1). To lower blade tip that tends to climb
during ground tracking at high rpm or
(1). To lower a blade tip, shorten pitch during forward flight, bend appropriate
control link assembly. To raise a blade tab section slightly downward; to raise
tip, lengthen pitch control link assem- tip of blade that tends to descend, bend
bly. Onesixth of a turn of link (one flat) tab slightly upward. If only slight track
raises or lowers blade tip approximately correction is necessary, limit tab
1/4 inch (6.35 mm). bending to width of bending tool. If
more correction is necessary, bend a
Center each rod end or pitch slightly wider section of tab. Use small
CAUTION case and/or swashplate wear adjustments to avoid excessive rebend-
will result. Ensure there is no binding in full ing of tabs.
up travel position.
NOTE: Tab zones on same blade can require
(2). After adjusting pitch control link bending in opposite directions. For example,
length, center each rod end in its fitting after bending tab zone A downward to get
and hold while tightening jam nuts; good tracking at 6090 knots, it might be-
safety with lockwire. come necessary to bend tab zone D or E (Ref.
Figure 502) upward to correct track at red-
C. Blade Tab Adjustment line airspeed. In any case, do not use larger
(Ref. Figure 502) Once ground idle track is tab corrections than are actually necessary.
obtained, all remaining tracking correction is (2). Each time blade tabs are adjusted,
accomplished by very slight bending of various recheck ground idle track and readjust
blade tab zones with tab bending tool (ST902). if necessary.
Different zones of tabs are used to adjust blade
track at different airspeeds. In general, tab (3). After completion of forward flight
zone A is used for highrpm, flat pitch ground tracking, balance and check autorota-
tracking (100% N2) and zones C, D, and tion rpm.
Page 502
Revision 34 181060
MAINTENANCE MANUAL
MAIN ROTOR BLADE BLADE STATIONS 93 99 105 111 117 124 130 148 164
(TOP VIEW)
71 IN.
(180 CM) 65 IN.
(165 CM) 59 IN.
(150 CM) 53 IN.
(135 CM) 47 IN.
(119 CM) 40 IN.
(102 CM 34 IN.
(86 CM) 16 IN.
(41 CM)
NOT USED
(NOTE 1) TAB ZONES E D A
NOTE 2 C B TO END OF
BLADE NOT USED
SHOCK CORD HIGH RPM GROUND (NOTE 1)
(OR EQUIVALENT) MEDIUM SPEED TRACKING AND UP TO
FLIGHT TRACKING 110 KNOTS IN FLIGHT
130145 KNOTS
(100% N2)
110130 KNOTS
HIGH SPEED IN FLIGHT
FLIGHT TRACKING (100% N2)
145152 KNOTS
(100% N2)
NOTES:
1. UNUSED TAB ZONES MUST BE MAINTAINED
STRAIGHT, NEUTRAL AND PARALLEL.
2. USE ONLY AS NECESSARY TO SUPPLEMENT
ZONE D TO AVOID EXCESSIVE TAB BENDING
POINTER IN ZONE D.
TAB BENDING TOOLS

BENDER
6G18017A
Figure 502. Adjustment Main Rotor Blade Tab

D. Main Rotor Ground Tracking NOTE: On new (untracked) blades, check that
all tab areas are straight and in neutral po-
sition (centered on chordline 0.0 0.5).
For best results, tracking should be performed
under calm air conditions. Wind velocity (2). Load helicopter to a gross weight of
should not exceed six knots during adjust- approximately 2350 pounds (1066.9 kg);
ments. Accurate adjustment of initial ground then ground idle (approximately
track is very important. In most instances, 6465% N1) with collective pitch stick
forward flight tracking problems can be full down.
avoided or greatly reduced by setting initial
track as nearly perfect as possible. Tolerances (3). Observe tracking tip cap reflector image
specified in following instructions should be by directing strobe light beam toward
considered maximum permissible deviation blade tip path and sweeping beam
rather than desired goal. slowly back and forth until reflector
images are clearly seen. Tracking image
should appear directly in front of
NOTE: If main rotor hub or a pitch control rod helicopter or slightly off helicopter
end bearing has been replaced, adjust pitch centerline.
control link(s) before proceeding with
ground tracking. (4). If blades are in track, tip cap reflector
image pattern should resemble image
A, (Ref. Figure 501) (no blade tip more
(1). Before tracking blades that are not new, than 1/4 of one tracking reflector
check that normally straight (not to be diameter, 1/8 inch (3.175 mm), above or
used) tab areas are in neutral position below adjacent reflectors). If blades are
(centered on chordline) and straight. in track, proceed with step (5). below. If
Page 503
181060 Revision 23
MAINTENANCE MANUAL
blades are out of track, adjust pitch Use of the tracking strobe
control links and repeat step (3). above. WARNING light in night flight is not
recommended. Such use can result in
(5). With collective pitch stick full down, pilot disorientation or loss of vision
increase engine speed to 100% N2 and with resultant damage to the helicop-
observe tip cap reflector image to see if ter and personal injury.
blade track is changed from ground idle
track. When all six blades are in track F. Forward Flight Tracking
within 1/4 of one reflector diameter,
(Ref. Figure 502 and Figure 506 thru
ground track is correct; proceed with
Figure 508) Forward flight tracking should be
hover verification. When a blade is out
performed whenever vertical flight vibrations
of track, adjust blade tab zone A until
indicate that blades may be out of track.
high rpm ground track is within
tolerance. (1). Verify helicopter gross weight of
20002500 pounds (9081135 kg).
E. Hover Track Verification
NOTE: When bending trim tabs, do not bend
(Ref. Figure 504) more than 1.5 between six inch sections.
(1). Hover track verification must be (2). Perform flight tracking from hover up
performed after ground tracking and to 110 knots at 100% N2. If flight track
before forward flight tracking. Verifica- varies from hover track more than 1/2
tion is only a check of hover track. Do inch (12.7 mm), bend tab zone A (five
not adjust pitch control links or blade degrees maximum) to limit variation to
tabs because of track images observed tab zone B (five degrees maximum).
during hovering. Tab adjustments often
cause variation between ground track (3). Check autorotation percentage; per-
and hovering track. A large track centage must not be less than 480
variation may indicate that one or more (90%).
blades is beyond its chordwise balance Do not attempt to adjust chord-
tolerance, but this can only be deter- CAUTION wise balance of a blade found to
mined during forward flight tracking. be faulty when performing banked turns.
Perform hover track verification as Chordwise balance corrections must be ac-
follows. complished by manufacturer (MDHI).
NOTE: Collective pitch stick may be heavy" af- (4). Perform a series of 45 degree banked
ter tracking reflectors are mounted on blade turns at 100 knots and observe track
tips. This condition is not unusual and may change from level flight. If any blade
be disregarded. climbs or dives more than one inch
(2.54 cm) out of track with others,
(2). Verify helicopter gross weight of
chordwise balance (center of gravity) of
20002500 pounds (9081135 kg).
that blade is beyond its tolerance and
(3). With collective pitch stick full down, blade must be replaced or balanced by
increase N2 to 100%. an MDHI Field Representative. (Hover
track variations of this type that do not
(4). Observe tracking reflector images to repeat during bankedturn maneuver
verify that ground track is within may be disregarded.)
limits.
(5). Perform flight tracking at 100% N2. If
(5). With helicopter in a stable hover, necessary, adjust tab zone B (five
observe reflector images. If one or more degrees maximum) to limit track
blades are out of track, record condi- variation to 1/2 inch (12.7 mm) or less
tion(s) for reference during forward and to minimize excessive vertical
flight tracking. (oneper revolution) vibration. If
variation is excessive, bend tab zone C
(6). Proceed with forward flight tracking. or D (five degrees maximum).
Page 504
Revision 23 181060
MAINTENANCE MANUAL
NOTE: When determining whether blade track NOTE: Change length of all six pitch control
is acceptable, overall vibration level of heli- links as necessary to adjust autorotation
copter should be determining factor. Some percentage. Be sure to lengthen or shorten
combinations of rotor blades might produce all six links exactly same amount or blade
higher sixperrevolution vibration as track is changed. One flat (1/6turn) of con-
blade tips are brought into close track; in trol link body causes approximately one per-
such cases, lowest vibration level is pre- cent change in autorotation percent.
ferred, even though observed blade track
may be beyond specified tolerances.
(6). After flight tracking is completed, (1). Autorotation Percentage Check (Ref.
perform a Main Rotor System Balance Table 502) Load helicopter to a gross
Procedure and Main Rotor Autorotation weight of 2800 25 pounds (1270 11
RPM Check. kg). Perform a practice autorotative
descent (Ref. RFM), taking care not to
2. Main Rotor System Balance Procedure allow percentage to exceed rotor speed
limitations. During autorotation, take
Balance the main rotor system according to
careful note of stabilized autorotation
instructions in the ChadwickHelmuth
percentage at one of the gross weight/
Operation and Service Instruction Handbook.
density altitude combinations. After
The maximum allowable bal- landing, compare observed percentage
CAUTION ance weight per leadlag bolt on with values. If observed percentage is
the main rotor hub assembly is 143 grams. within limits in table, percentage
setting is correct. If limits were exceed-
3. Main Rotor Autorotation Percentage ed, make corrective adjustments
Check according to Autorotation Percentage
(Ref. Table 502) An autorotation percentage Adjustment, until percentage is within
check is required after each blade tracking limits.
operation and whenever rpm is outside limits
listed. Check rotor rpm and make adjustments
as follows. (2). Autorotation Percentage Adjustment:
Change length of all six pitch control
CAUTION links as required to adjust autorotation
percentage. Make certain all six links
D All autorotation percentage adjustments are shortened or lengthened exactly the
shall be made at the main rotor pitch con- same amount or blade track will be
trol links only. Do not readjust mixer altered.
control rods after rigging is accomplished.
Failure to observe this precaution may re-
sult in serious damage to rotor system NOTE: After autorotation percentage adjust-
and controls. Do not adjust control rod ments are satisfactorily accomplished, re-
end beyond witness hole. move tracking equipment before returning
D Tracking targets reduce blade to tailboom helicopter to service. Be sure to correctly
clearance, performing autorotations to tighten and safety all bolts after they are re-
the ground could result in boom strikes. installed.
Page 505
181060 Revision 23
MAINTENANCE MANUAL
Table 501. Summary Procedure for Blade Tracking

Satisfactory Unsatisfactory
Step Result Result Corrective Action
(1) Observe ground track. Go to step (2). Ref. Corrective Adjust pitch control rods and blade tabs
Action. as required. Repeat track observation.
(2) Perform hover verification. Go to step (3). Ref. Corrective Record track verification and proceed with
Action. forward flight tracking.
(3) Perform forward flight Go to step (4). Ref. Corrective Adjust blade tabs and repeat forward
tracking. Action. flight tracking.
(4) Perform autorotation Go to step (5). Ref. Corrective Adjust autorotation percentage and
percentage check. Action. repeat percentage check.
(5) Remove tracking equipment
and return helicopter to service.
NOTE: Ground rock or stick shake with rotor blades in track during ground track indicates rotor blades are not
properly phased.
Table 502. Autorotation Percentage Chart

Stabilized Autorotation Percentage at Density Altitude
Gross Wt 1000 Ft 2000 Ft 3000 Ft 4000 Ft 5000 Ft

lb/kg Sea Level (305 M) (610 M) (915 M) (1220 M) (1525 M)
2500/1134 93.8 95.8 94.6 96.6 95.4 97.4 96.3 98.3 97.1 99.1 98.0 100.0
2600/1179 95.6 97.6 96.4 98.4 97.3 99.3 98.1 100.1 99.0 101.0 99.9 101.9
2700/1224 97.4 99.4 98.2 100.2 99.1 101.1 100.0 102.0 100.9 102.9 101.8 103.8
2800/1270 99.2 101.2 100.0 102.0 100.9 102.9 101.8 103.8 102.7 104.7 103.6 105.6
2900/1315 101.0 103.0 101.8 103.8 102.7 104.7 103.6 105.6 104.6 106.4
3000/1361 102.7 104.7 103.6 105.6 104.5 106.4 105.4 106.4
NOTE: Perform autorotation percentage checks at gross weight/density altitude combinations for which percent-
age values are given. Blank spaces indicate that application of collective pitch may be necessary to avoid rotor
overspeed.
Page 506
Revision 23 181060
MAINTENANCE MANUAL
MAIN ROTOR
BALANCE WEIGHTS
(NOTE) MAIN ROTOR
LEADLAG BOLT
NOTE:
THE MAXIMUM ALLOWABLE BALANCE WEIGHT
PER LEADLAG BOLT ON THE MAIN ROTOR HUB
ASSEMBLY IS 143 GRAMS.
6G18019A
Figure 503. Main Rotor System Balancing
Page 507
181060 Revision 23
MAINTENANCE MANUAL
ROTATION
BLUE MD600N HOVER PITCH LINK ADJUSTMENT

VELO.
WHITE 1. TAKE READINGS AT IGE HOVER USING VERTICAL

YELLOW
VELOCIMETER ON CONSOLE.
2. ADJUST PITCH CHANGE LINK IN FLATS. 1 FLAT=1/6 TURN
OF PITCH CHANGE BARREL.
3. BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
MAG P/U
ATTACHED TO DRIVE LINK OF ROTATING SWASHPLATE.
4. TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED
RED
ON INSTRUMENT PEDESTAL POINTING DOWN.
5. ADJUST PITCH CHANGE LINK BEFORE BALANCING AT HOVER.
GREEN
BLACK
ADJUSTMENT IN FLATS
OF PITCH LINKS
BLADE ORIENTATION WITH
DRIVE LINK INTERRUPTER MOVE MOVE
RED GREEN
UP UP 3 MOVE
3 3 BLACK
AIRCRAFT VIEWED FROM ABOVE 1 1/2
1 1/2 UP
MOVE 3 O 12:00
BLACK 11:00 1:00
1 1/2
UP MOVE
IPS 1 1/2 YELLOW
ADJUST .8 O
CLOCK 2:00 UP
10:00 .6 1 1/2
MOVE O .4 3
WHITE .2
UP 1 1/2 .8
.6 .4 .2
9:00 3:00 3
3
MOVE
1 1/2 GREEN
UP
3 0
1 1/2 4:00
8:00
0
1 1/2
1 1/2 7:00 MOVE

5:00 BLUE
6:00 0 3
UP
MOVE 1 1/2
BLUE 1 1/2 3
3
UP MOVE
3
YELLOW
MOVE UP
WHITE
UP
NOTES:
1. ARROWS INDICATE DIRECTION POINT SHOULD GO WHEN
ADJUSTMENT TO NOTED BLADE IS MADE.
2. MOVE TO OPPOSITE BLADE IN OPPOSITE DIRECTION HAS
SAME EFFECT.
6G18099
Figure 504. Main Rotor Track at Hover (Pitch Change Link Adjustment)
Page 508
Revision 23 181060
MAINTENANCE MANUAL
ROTATION
BLUE
WHITE YELLOW
MD600N HOVER BALANCE CHART
1. TAKE READINGS AT IGE HOVER AFTER PCL TRACK.

2. USE WEIGHT, IN GRAMS, AT HUB LOCATION.
RED ATTACHED TO DRIVE LINK OF ROTATING SWASHPLATE.
GREEN
4. LATERAL VELOCIMETER READINGS USING VELOCIMETER
AT LEADING SIDE OF CONTROLS COVER POINTING TO
BLACK LEFT OF AIRCRAFT.
BLADE ORIENTATION WITH

DRIVE LINK INTERRUPTER
OVER MAGNETIC PICKUP
AIRCRAFT VIEWED FROM

ABOVE
IPS
ADJUST
CLOCK
G181007
Figure 505. Main Rotor System Balance Chart
Page 509
181060 Revision 23
MAINTENANCE MANUAL
ROTATION
MD600N VERTICAL TAB CHART 100130 KIAS
BLUE 1. TAKE READINGS AT 100130 KIAS.
2. TAB MEASUREMENTS ARE IN 0.001 IN. (0.0254 MM).
VELO. 3. BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
WHITE YELLOW 4. TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED ON
INSTRUMENT PEDESTAL POINTING DOWN.
RED GREEN
BLACK
1. INNER TAB TWO WIDTHS OF BENDER (STA. 97 111)

2. MIDDLE TAB TWO WIDTHS OF BENDER (STA. 111 130)
BLADE ORIENTATION WITH 3. OUTER TAB ONE WIDTH OF BENDER (STA. 130 142)
AIRCRAFT VIEWED FROM

ABOVE
IPS
ADJUST
CLOCK
NOTE:
ARROWS INDICATE DIRECTION POINT SHOULD GO
WHEN ADJUSTMENT TO NOTED BLADE IS MADE.
G181006A
Figure 506. Main Rotor Tracking at 100 130 KIAS (Inner Tab Adjustment)
Page 510
Revision 37 181060
MAINTENANCE MANUAL
ROTATION
BLUE
1. TAKE READINGS AT 100130 KIAS.
VELO.
2. TAB MEASUREMENTS ARE IN .001 INCH.
WHITE YELLOW 3. BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
4. TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED ON

RED

GREEN NO BEND
AREA
BLACK TAB BENDER TWO WIDTHS
1. UNDER TAB TWO WIDTHS OF BENDER (STA 97 111)

2. MIDDLE TAB TWO WIDTHS OF BENDER (STA 111 130)
BLADE ORIENTATION WITH 3. OUTER TAB ONE WIDTH OF BENDER (STA 130 142)
.010 WHITE
AIRCRAFT VIEWED FROM ABOVE RED
.005
BLACK
.005
IPS
ADJUST .010
CLOCK 1.0 IPS 12:00 .005
BLUE 0
11:00 1:00
.005 0 .8
.6 RED
.010
.005
10:00 2:00
.4
WHITE
.005 .2
0
9:00
.2
0 .4 .8
.6 .005
1.0 IPS
GREEN
8:00 4:00
.005
.010
.005
0
YELLOW 7:00 5:00
0 BLACK
.005 6:00
.010
.005 .005
BLUE
YELLOW
GREEN .010
6G18100
Figure 507. Main Rotor Tracking at 100 130 KIAS (Mid Tab Adjustment)
Page 511
181060 Revision 23
MAINTENANCE MANUAL
ROTATION
BLUE
VELO.
1. TAKE READINGS AT 100130 KIAS.
WHITE YELLOW 2. TAB MEASUREMENTS ARE IN .001 INCH
4. TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED ON

RED

GREEN NO BEND
AREA
BLACK ONE WIDTH OF TOOL
1. UNDER TAB TWO WIDTHS OF BENDER (STA. 97 TO 111)

2. MIDDLE TAB TWO WIDTHS OF BENDER (STA. 111 TO 130)
BLADE ORIENTATION WITH 3. OUTER TAB ONE WIDTH OF BENDER (STA. 130 TO 142)
OVER MAGNETIC PICKUP BLACK
WHITE UP
UP .016
AIRCRAFT VIEWED FROM ABOVE
.016
.008 .008 RED

RED
IPS
ADJUST UP
CLOCK 12:00 .008
.008 11:00 1:00
10:00 2:00 GREEN

.008
BLUE 1.0 IPS
UP .8 .8
.008 1.0 IPS .6 .016
.4 .4 .6
.2 .2
9:00 3:00
.016 .008
1.0 IPS BLACK
.008 UP
WHITE 8:00 4:00
.005
UP
7:00 5:00 .008

.008 6:00
YELLOW
.008 UP
.008
YELLOW
UP .016
.016
GREEN
BLUE
UP
UP
6G18101
Figure 508. Main Rotor Tracking at 100 130 KIAS (Outer Tab Adjustment)
Page 512
Revision 23 181060
MAINTENANCE MANUAL
Section
182000
Tail Rotor Balance
MAINTENANCE MANUAL
TAIL ROTOR BALANCE

1. Tail Rotor Balancing procedure. Tail rotor balance spare kit
contains extra tip weights and screws.
Special Tools (2). Install combination of weights required.
(Ref. Section 910000) Maximum weight permitted is thirty
Item Nomenclature four grams at each tip (Ref. Table 201).
ST903 Balancer/analyzer instrument kit Torque screws to 21 24 inchpounds
(2.37 2.71 Nm).
B. Balance at Blade Pitch Arm
Balancing is accomplished by use of a balanc-
ing kit (ST903). The carrying case of this kit (Ref. Figure 201) Weight increase at light pitch
contains all instrumentation, balance charts arm may be obtained by removal of equivalent
and miscellaneous items needed to balance the washer weight from opposite pitch arm.
tail rotor. Also included is a track and balance Always remove washers from opposite pitch
handbook for use with the equipment to arm, if installed, and subtract from weight to
correct balance when such can be obtained by be added before adding more weight. For
addition or subtraction of weight at pitcharm washer data, refer to Table 201. Main rotor
studs or at blade tips. and tail rotor balancing spare kit contains
extra washers. Maximum washer weight
Since vibration reduction by weight adjust- allowed at either pitch arm bolt is 26.91 grams
ment is dependent on proper mechanical (23 washers).
condition of the tail rotor and tail rotor drive
system, troubleshooting information (Ref. NOTE:
Chap. 64) should be used with balancing kit D A tail rotor outofbalance condition that
instructions. Acceptance criteria for balance cannot be corrected by standard balanc-
and vibration are contained in the balancing ing procedures may be an indication of ex-
kit and on each balance chart. Main rotor and cessive play in tail rotor hub components.
tail rotor balancing spare kit contains spare
screws, washers and tip weights. D There is possibility of slight weight varia-
tion between pitch control links.
NOTE: If tail rotor balance is difficult to (1). If tail rotor has maximum balance
achieve and horizontal stabilizer resonance
washer weight allowed on one pitch
is noted refer to 421087505 Horizontal
arm, compare the two links.
Stabilizer Tab Weight Installation.
(2). If pitch link opposite the weight
A. Balance at Blade Tip requirement appears larger, exchange
one link for the other and repeat
When balancing procedures indicate that vibration analysis.
weight should be added to a tip, it is prefer-
able, if possible, to instead remove an equiva- (3). If, as a result of parts peculiarity,
lent amount from the opposite tip to keep maximum allowable weight at one pitch
overall weight to a minimum. Installation of arm does not correct assembly balance,
tip weights is not mandatory. However, open tail rotor hub may be shifted in fork
screw holes are not permitted; screws must be and hubtofork shimming adjusted, if
installed. Shorter than normal screws may be maximum allowable play in fork
used for balance if minimal thread engage- bearings is not exceeded. This is done
ment of 5/16 inch (7.9375 mm) exists. by transferring forktohub spacing
shims from balance weighted side to
(1). Remove tipweight screws and weights opposite side of hub, according to hub
(Ref. Figure 201). Select balancing and fork assembly procedures (Ref.
hardware indicated by balancing COM).
Page 201
182000 Revision 34
MAINTENANCE MANUAL
(a). Chordwise weight shift resulting (6). Initially balance the tail rotor until
from each 0.001 inch (0.0254 mm) of vibration level is 0.1 IPS (0.85 MIL) or
spacing thickness transferred less as follows:
reduces weight requirement at
weighted pitch arm by one (a). Add weights to blade tips only. For
HS306227L balance washer. fourbladed tail rotor, divide weights
as necessary between the two lower
(b). Transferring one 369A171753 blades to make the total weight
spacing shim, 0.010 inch (0.254 mm) vector in the downward direction.
thickness, allows initial removal of
10 thin washers from pitch arm and NOTE: If more than 15 grams of tip weight (in-
thereby allows more flexibility for cluding screw) is necessary on any one
further balance correction during blade, use the long method balance proce-
vibration analysis. dure.
(7). After initial balance, reset RPM TUNE
(4). It should be noted that spanwise dial, according to ChadwickHelmuth
balance is probably affected by any Handbook for final balancing. Direct
chordwise shift of fork. strobe at tail rotor and adjust per
ChadwickHelmuth instructions for
(5). If maximum allowable play in fork VERIFY TUNE. Apply the same
bearings is exceeded, bearings must be method used for initial balance to
replaced (Ref. COM). balance until vibration level is 0.1 IPS
(0.85 MIL) or less.
(6). Replacement or adjustment of parts
requires balancing of tail rotor follow- D. Long Method Balance Check
ing reassembly. (FourBladed Tail Rotor)
C. Short Method Balance Check (Ref. Figure 203 and Figure 204) A long
method balance check must be accomplished
(Ref. Figure 201 and Figure 202) Use tail rotor each time hubs and fork of fourbladed tail
vibration analyzer (ST903) throughout this rotor are reassembled. Use tail rotor vibration
procedure. analyzer (ST903) throughout the procedure.
First runup of tail rotor assem-
(1). Mount accelerometer into tail rotor CAUTION bly should be accomplished in a
gearbox breather plug as noted in
ChadwickHelmuth Operation and cautious manner, increasing tail rotor rpm
Service Handbook. slowly so that vibrations from outofba-
lance tail rotor assembly will not cause dam-
(2). Connect accelerometer and balancer DC age.
power cables as noted in the Chadwick NOTE: Prior to performing long method bal-
Helmuth Operation and Service ance check, ensure hub is centered on fork
Handbook. and elastomeric bearings are preloaded cor-
rectly.
(3). Apply a retroreflective target material
on blade root fitting. For fourbladed (1). With outboard blade removed, balance
tail rotor, one blade of the outboard tail inboard blade by adjusting tip weights
rotor assembly. and washers at pitch arm bolt to
achieve 0.10 IPS (0.85 MIL) or less
(4). Connect cables and instruments and vibration level at 2100 rpm (input shaft
adjust settings as noted in Chadwick of transmission). This corresponds to
Helmuth Handbook. tail rotor rpm of 2168.
(5). Direct strobe at tail rotor and adjust (2). Install outboard blade and hub assem-
per ChadwickHelmuth instructions for bly; check balance of outboard blades by
VERIFY TUNE. adjusting weights to obtain 0.10 IPS
Page 202
Revision 23 182000
MAINTENANCE MANUAL
(0.85 MIL) vibration or less, using same assembly and balance the tail rotor
method as used for inboard blade assembly.
balancing, except as shown in
Figure 204. (3). After balancing the tail rotor assembly,
reinstall the horizontal stabilizer.
2. Horizontal Stabilizer Tuning (4). Run engine at 102%105% N2 and
observe horizontal stabilizer tab.
Installation of tab weight is optional on the
421087 505 horizontal stabilizer if difficulty (5). If tab resonance occurs and tail rotor
in tail rotor balance and horizontal stabilizer balance is no longer acceptable, install
tab resonance vibration is encountered. tab weight to horizontal stabilizer right
tab (Ref. Sec. 535010, Horizontal
(1). With helicopter on flat smooth surface, Stabilizer Tab Weight Installation).
operate engine at 102%105% N2 and (6). If needed, a one ounce weight may also
observe horizontal stabilizer tab. be installed on left tab.
(2). If tab resonance vibration occurs, (7). A maximum of two ounces may be
remove the horizontal stabilizer installed on each tab.
Page 203
182000 Revision 23
MAINTENANCE MANUAL
ACCELEROMETER/VELOMETER
FOR TAIL ROTOR BALANCING.
INSTALL ON BREATHER PLUG
OF TAIL ROTOR GEAR BOX
TAPE
SECURE UNDER LATCH

REFLECTIVE
TAPE
KIT LOCATION FOR TAIL

28VDC POWER CABLE ROTOR BALANCING
TO AUXILIARY OUTPUT
RECEPTACLE
BALANCE WASHERS
RETAINING NUT
PITCH ARM BOLT

CABLE
SPRING WASHER
PITCH CONTROL
ACCELEROMETER/VELOMETER LINK
(NOTE 1)
PITCH ARM
BREATHER/FILLER BALANCE WASHER
INSTALLATION
TIP WEIGHT
NOTE 3
WEIGHT INSTALLATION
ROTATED
NOTES:
1. INSTALLED ONLY FINGER TIGHT.
2. FOR INFORMATION ON MAXIMUM WEIGHT, NUMBERS, TYPES AND
EXACT LOCATIONS OF BALANCING HARDWARE TO BE USED,
REFER TO ASSOCIATED TEXT AND TABLES.
3. TORQUE SCREWS TO 21 24 INCHPOUNDS (2.37 2.71 NM).
G182000B
Figure 201. Tail Rotor Assembly Balancing (TwoBladed Tail Rotor)
Page 204
Revision 34 182000
MAINTENANCE MANUAL
Table 201. Tail Rotor Balance Weight Value Chart

At Blade Tip (4) At Blade Pitch Arm (3)
Screw (5) Washer (1)(2)

Length Weight Thickness Weight OD
Part Number (in./mm) (Grams) Part Number (in./mm) (Grams) (in./mm)
NAS13520812P 0.75/19.05 2.22 HS306227L 0.016/0.4064 1.17 0.800/20.32
NAS13520814P 0.875/22.23 2.44
Weight
Thickness Weight
(In./mm) (Grams)
369A16223 0.016/0.4064 0.29
369A16225 0.036/0.9144 1.76
NOTES:
(1) Used on balance bolt.
(2) Maximum of 23 washers is permitted on each balance bolt.
(3) Minimum of two threads must extend past nut securing balance washers on balance bolt.
(4) Maximum weight, including screws, is 34 grams.
(5) Minimum screw thread engagement is 5/16 inch (7.9375 mm).
TOTAL
TOTAL WEIGHT
TOTAL WEIGHT
SMALLER VECTOR
WEIGHT VECTOR
WEIGHT
VECTOR
EQUAL EQUAL
WEIGHT WEIGHT LARGE WEIGHT
WEIGHT
OR OR
NOTE:
IF, WHEN ADDING WEIGHTS, OUTOFBALANCE VIBRATION
LEVEL INCREASES, ADD WEIGHTS TO THE TOP BLADE(S). G182001
Figure 202. Short Method Tail Rotor Balancing (FourBladed Tail Rotor)
Page 205
182000 Revision 39
MAINTENANCE MANUAL
BALANCE WASHERS
(NOTE 1)
SHIMS
(NOTE 2)
NOTES: SHIM
1. MAXIMUM ALLOWABLE NUMBER OF WASHERS AT
PITCH ARM BOLT IS 23. WHENEVER THIS LIMIT IS
REACHED AND REQUIRED BALANCE CANNOT BE
MET, SHIFT THE CENTER OF THE HUB BY
TRANSFERRING SHIMS, THICKNESS OF 0.010 IN.
(0.254 MM), FROM WEIGHTED PITCH ARM SIDE TO
THE OPPOSITE SIDE AS SHOWN AND RECHECK
BALANCE, STARTING FROM ZERO WASHERS.
2. REMOVE 0.010 IN. (0.254 MM) THICK SHIM FROM G182002A
PITCH ARM SIDES AND TRANSFER THE SHIM TO
THE OPPOSITE SIDE.
Figure 203. Long Method Tail Rotor Balancing (Inboard Blade)
BALANCE WASHERS
(MAX. 23)
SHIMS
(NOTE 2)
SHIM
NOTES:
1. REMOVE 0.010 IN. (0.254 MM) THICK SHIM
FROM WEIGHTED PITCH ARM SIDE AND
TRANSFER THE SHIM TO THE OPPOSITE SIDE.
2. DURING BALANCE OF OUTBOARD BLADES,
WEIGHTS ON INBOARD BLADES MUST NOT G182003A
BE CHANGED.
Figure 204. Long Method Tail Rotor Balancing (Outboard Blade)
Page 206
Revision 23 182000
MAINTENANCE MANUAL
Section
182030
NOTARr
AntiTorque System
Fan Balance
MAINTENANCE MANUAL
NOTARR ANTITORQUE SYSTEM FAN BALANCE

1. Fan Balancing (4). Install velometer on bracket located at
the 6:00 oclock position (Ref.
The NOTARr antitorque system uses a Figure 203).
fandriven air circulation system within the
tailboom to control the directional heading of (5). Install magnetic pickup and velometer
the helicopter. The rudder pedals in the cockpit wiring (Ref. Figure 203).
control the blade angle of the fan assembly.
Wiring must be secured to pre-
The fan assembly operates at a constant speed CAUTION vent them from being ingested
of 5388 RPM at 100% N2.
into the fan assembly during runup.
Balancing is accomplished by use of a balanc- (6). Position the antitorque pedals at
ing kit. The carrying case of this kit contains neutral during fan balancing.
all instrumentation, balance charts and
miscellaneous items needed to balance the fan NOTE: The neutral position is 62% from full
assembly. Also included is a track and balance left or approximately one inch of right pedal
handbook for use with the equipment to from pedals centered. This pedal position
correct balance when such can be obtained by produces minimum fan pitch and closes the
addition or subtraction of weight at studs on thruster.
the fan assembly.
WARNING
Since vibration reduction by weight adjust-
ment is dependent on proper mechanical D Damage could occur if the anti
condition of fan drive system, troubleshooting torque pedals are not kept at neutral
information (Ref. Chap. 64) should be used while the helicopter is operating
with balancing kit instructions. Acceptance with the fan/hub transmission fair-
criteria for balance and vibration are con- ing removed.
tained in the balancing kit and on each D Operators and authorized observers
balance chart. should remain in the designated
areas during balancing operations.
2. Fan Balance Check
D Wearing loose clothing or having ma-
terials in shirt pockets during opera-
(Ref. Figure 201) tions can result in injury to person-
nel and/or damage to aircraft.
Special Tools
(7). Run helicopter to establish N2 speed of
100% percent.
Item Nomenclature
ST903 Balancer/analyzer instrument kit (8). Observe vibration reading.
(a). If vibration reading is greater than
NOTE: Use the vibration analyzer (ST903) 0.2 ips, shut down helicopter and
throughout this procedure. proceed with step (9).
(b). If vibration level is 0.2 ips or less,
(1). Remove fan inlet screen. proceed with step (11).
(2). Remove upper portion of the fan/hub (9). Add hardware to the balancing studs in
transmission fairing. any combination as required using
Table 201 and Figure 202. Torque nuts
(3). Number balancing studs as shown in on studs to 30 40 inch pounds (3.39
Figure 201 using a permanent marker. 4.52 Nm).
Page 201
182030 Revision 23
MAINTENANCE MANUAL
Do not over torque the nuts on (11). Remove balancing equipment wiring
CAUTION the balancing studs. An over and attachments.
torqued nut may cause the stud locking col-
lar to become loose the next time the nut is (12). Install the fan/hub transmission fairing
removed. and fan inlet screen.
(10). Repeat steps (6). thru (9). until fan
dynamic balance is 0.2 ips or less.
Table 201. Preferred Hardware for Balancing Fan Assembly
Washer Weight (grams)
Stainless Thickness ID OD Stainless
Aluminum Steel (in/mm) (in/mm) (in/mm) Aluminum Steel
AN960KD416L 0.016 / 0.406 0.265 / 6.731 0.500 / 12.700 0.103
AN960C416L 0.016 / 0.406 0.265 / 6.731 0.500 / 12.700 0.572
AN960KD416 AN960C416 0.063 /1.600 0.265 / 6.731 0.500 / 12.700 0.407 1.144
HS306325L HS306225L 0.016 / 0.406 0.263 / 6.680 0.528 / 13.411 0.121 0.339
HS306325 HS306225 0.032 / 0.813 0.263 / 6.680 0.528 / 13.411 0.241 0.677
HS306325H HS306225H 0.063 / 1.600 0.263 / 6.680 0.528 / 13.411 0.482 1.355
HS306326L HS306226L 0.016 / 0.406 0.263 / 6.680 0.619 / 15.723 0.181 0.507
HS306326 HS306226 0.032 / 0.813 0.263 / 6.680 0.619 / 15.723 0.361 1.015
HS306326H HS306226H 0.063 / 1.600 0.263 / 6.680 0.619 / 15.723 0.723 2.029
HS306327L HS306227L 0.016 / 0.406 0.263 / 6.680 0.800 / 20.320 0.329 0.922
HS306327 HS306227 0.032 / 0.813 0.263 / 6.680 0.800 / 20.320 0.657 1.844
HS306327H HS306227H 0.063 / 1.600 0.263 / 6.680 0.800 / 20.320 1.314 3.689
NOTE: Maximum washer stackup thickness = 0.20 inch (5.08 mm).
Page 202
Revision 23 182030
MAINTENANCE MANUAL
FAN ROTATION
MAGNETIC PICKUP
INTERRUPTER
1
13
2
12
11
10
9
6
8
7
BALANCING STUD
(13 PLACES)
VIEW LOOKING AFT
G182006
Figure 201. Fan Balancing Stud Numbering
Page 203
182030 Revision 23
MAINTENANCE MANUAL
12
350 360 10
340 IPS GRAMS 20
11 1.0 5.60 1
330 30
.9 5.04 #3
320 #4
40
.8 4.48
310 .7 3.92 50
#5 #2
.6 3.36
10 300 2
60
.5 2.80
.4 2.24
290 70
#6 .3 1.68
280 .2 1.12
80
.1 .56 #1
270
9 3
#7
260 100
#13
110
250
240
#8 #12 120
8 4
230 130
220 #9 140
#11
#10
210 150
7 200 160 5
190 180 170
G182007
Figure 202. Fan Balance Chart
Page 204
Revision 23 182030
MAINTENANCE MANUAL
MAGNETIC PICKUP/
VELOMETER CABLES
28 VDC POWER CABLE

TO AUXILIARY OUTPUT KIT LOCATION FOR
FAN BALANCING
RECEPTACLE
GAP 0.060 IN. (1.524 MM)
FAN / HUB MAGNETIC PICKUP

TRANSMISSION
FAIRING
VELOMETER
BALANCING STUD
(13 PLCS)
G182008A
Figure 203. Fan Balancing Equipment Installation

182030 Revision 23
MAINTENANCE MANUAL
Chapter
20
Standard Practices
MAINTENANCE MANUAL
TABLE OF CONTENTS
201000 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Application of Torque Wrench Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Bearings Installation, Staking or Swaging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Control Tube Jam Nut Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Standard Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Recommended Standard Torques for TensionType Fasteners . . . . . 203
Table 202. Recommended Standard Torques for ShearType Fasteners . . . . . . . 204
Table 203. Locking (Drag) Torque for SelfLocking Fasteners . . . . . . . . . . . . . . . 205
202000 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fuselage Interior Trim and Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Airframe Exterior and Rotor Blades Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Transparent Plastic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Engine Compressor Contamination Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Cleaning Of Engine Air Inlet Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
203000 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Paint Touchup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Touchup Small Sanded Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Touchup Flaking or Dried Paint or Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Touchup Primer Not Adhering to Metal Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Touchup Glass Fiber Laminate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Touchup Polycarbonate Plastic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
F. Touchup ABS Thermoplastic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Main Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Main Rotor Blade Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Main Rotor Blade Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Tail Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Tail Rotor Blade Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Tail Rotor Blade Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
204000 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page i
MAINTENANCE MANUAL

2. Magnesium Alloys Insulation Against Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Sealing Compound Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Main Rotor Hub Corrosion Prevention (TriFlow Wash Procedure) . . . . . . . . . . . . . 201
5. Main Rotor Blades Corrosion Arresting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Main Rotor Blade and Damper Attach Pins Corrosion Prevention . . . . . . . . . . 202
6. Magnesium Alloy Exterior Surface Touchup Treatment . . . . . . . . . . . . . . . . . . . . . . . 203
7. Aluminum Alloy Exterior Surface Touchup Treatment . . . . . . . . . . . . . . . . . . . . . . . . 203
8. Steel Alloy Exterior Surface Touchup Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9. Splitter Bungee Spring Corrosion Control (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Table 201. AntiCorrosion Chemical Finishes Aluminum . . . . . . . . . . . . . . . . . . 204
209000 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Nondestructive Inspection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Visual Inspection Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Dye Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Coin Tap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Fluorescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Coin Tap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
F. Eddy Current Inspection General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Page ii
MAINTENANCE MANUAL
Section
201000
Torque
MAINTENANCE MANUAL
TORQUE
1. Torque Wrenches (5). Torque values specified in this manual
are special torque values that apply
Torque wrenches should be of good quality and instead of those listed.
calibration should be verified at regular
intervals to verify accuracy. Torque wrench (6). If adapters are used such that adapter
accuracy at room temperature, 70F (22 C) and torque wrench are not at right
must be within following limits. angles (90 degrees) to each other,
wrench or indicator reading must be
(1). From zero through 19 percent of torque corrected.
wrench range, error may not exceed 7
percent of load applied. (7). Any reuse of selflocking nuts over 3/8
inch is governed by values listed in
(2). From 20 thru 79 percent of torque Table 203.
wrench range, error may not exceed 4
percent load applied. (8). Castellated nuts aretorqued to the
minimum side of the recommended
(3). From 80 to 100 percent of torque torque range. Continue to tighten the
wrench range, error may not exceed 5 nut until the hole of the cotter pin lines
percent of load applied. up with the castellation without
exceeding the maximum specified
2. Application of Torque Wrench Loads torque.
(Ref. Table 201 thru Table 203) Recommended (9). Bolt must not be rotated during
tightening torque values and minimum drag application of torque to mating nut.
torque values for fine and coarse thread nuts,
and minimum breakaway torque for used 3. Bearings Installation, Staking or Swaging
selflocking bolts or screws are listed in Force
Table 201 and Table 202. Requirements
The following procedure explains how to
governing application of torque loads follow.
convert from a given Force which is required
These requirements apply throughout this
to perform a task to a proper hydraulic
manual except where otherwise specifically
pressure reading.
indicated.
(1). Determine the diameter of the ram
(1). Values apply to cadmiumplated bolts, (staking or swaging contact surface) on
cadmiumplated nuts coated with the hydraulic press to be used.
molybdenum disulfide (MoS2).
NOTE: The hydraulic press to be used must
(2). Manufacturer applied lubricant must have a pressure gauge.
not be removed nor additional lubricant
added. (2). Divide the ram diameter by two to get
the radius.
(3). Bolts, nuts and surfaces they bear on
must be clean, dry and free of lubricant (3). Multiply 3.14159 (pi) times the Radius
except as stated in requirement above. squared (R2). This will give the area of
the ram.
(4). Turning (drag) torque required to
install selflocking nut or bolt up to (4). Divide the force required for the task by
point of final tightening must always be the area of the ram. This gives the
added to final torque value specified or actual PSI reading for the hydraulic
the maintenance instruction, as press pressure gauge needed to perform
applicable. the task.
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MAINTENANCE MANUAL
EXAMPLE: 5. Standard Hardware Torque Values

Ram Diameter = 2.65 in. (6.731 cm) The following tables list torque values for
Ram Radius (R) = 1.325 in. (3.366 cm) standard hardware by part number.
Radius squared (R2) = 1.756 in.2 (8.548 cm2) NOTE: If unsure of hardware type, refer to
CSPIPC4.
R2 X 3.1416 = 5.517 in. (26.854 cm) (Area of
ram) (1). Table 201 lists selflocking tension
Force required = 75008500 lbs. (34023856 type fastener torque values.
kg) (variable)
(2). Table 202 lists sheartype fastener
75008500 lbs. (34023856 kg) / 5.517 in. torque values.
(26.854 cm) = 13591540 PSI (937010618
kPa) (3). Table 203 lists maximum and minimum
selflocking fastener drag (runon)
PSI required =1359 PSI (9370 kPa) Min.
torque values.
1540 PSI (10618 kPa) Max.
Force needed/(R2) X 3.1416 = Pressure Gauge CAUTION
Table 203 lists selflocking
Reading (runon) torque values, i.e.;
torque required to overcome the friction of
4. Control Tube Jam Nut Torquing the selflocking feature of fastener threads
prior to clampup and final tightening. Any
(1). Tighten jam nuts against control rods selflocking fastener that can be run down
by holding rodend with wrench. with the fingers after the locking feature en-
NOTE: Do not tighten with rodend against fit- gages must be replaced. Determine final
ting. torque value by adding the runon torque to
the specified final clamping torque. Final
(2). Ensure rodends are not preloaded after clamping torque values are listed in
torquing jam nuts. Table 201 and Table 202.
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Revision 38 201000
MAINTENANCE MANUAL
Table 201. Recommended Standard Torques for TensionType Fasteners

Diameter Thread Recommended Maximum Thread Recommended Maximum
inch Size Torque Allowable Size Torque Allowable
(mm) (Fine) in. lb (Nm) in. lb (Nm) (Coarse) in. lb (Nm) in. lb (Nm)
0.1640 12 15 20 12 15 20
8 36 8 32
(4.1656) (1.13 1.36) (2.26) (1.36 1.69) (2.26)
0.1900 20 25 40 20 25 35
10 32 10 24
(4.8260) (2.26 2.82) (4.52) (2.26 2.82) (3.95)
0.250 50 70 100 40 50 75
1/4 28 1/4 20
(6.350) (5.65 7.91) (11.30) (4.52 5.65) (8.47)
0.3125 100 140 225 80 90 160
5/16 24 5/16 18
(7.9375) (11.30 15.82) (25.42) (9.04 10.17) (18.08)
0.3750 160 190 390 160 185 275
3/8 24 3/8 16
(9.5250) (18.08 21.47) (44.06) (18.08 20.90) (31.07)
0.4375 450 500 840 235 255 475
7/16 20 7/16 14
(11.1125) (50.84 56.49) (94.91) (26.55 28.81) (53.67)
0.50 480 690 1100 400 480 880
1/2 20 1/2 13
(12.70) (54.23 77.96) (124.3) (45.19 54.23) (90.39)
0.5625 800 1000 1600 500 700 1100
9/16 18 9/16 12
(14.2875) (90.39 112.98) (180.8) (56.49 79.09) (124.3)
0.6250 1100 1300 2400 700 900 1500
5/8 18 5/8 11
(15.8750) (124.3 146.9) (271.2) (79.09 101.69) (169.5)
0.750 2300 2500 5000 1150 1600 2500
3/4 16 3/4 10
(19.050) (259.9 282.5) (565.0) (129.95 180.8) (282.5)
0.8750 2500 3000 7000 2200 3000 4600
7/8 14 7/8 9
(22.2250) (282.5 339.0) (791.0) (248.6 339.0) (542.4)
1.00 3700 5500 10000 3700 5000 7600
1 12 18
(25.40) (418.1 621.5) (1130.0) (418.1 565.0) (858.8)
1.1250 5000 7000 15000 5500 6500 12000
11/8 12 11/8 8
(28.5750) (565.0 791.0) (1695.0) (621.5 734.5) (1356.0)
1.250 9000 11000 25000 6500 8000 16000
11/4 12 11/4 8
(31.750) (1017.0 1243.0) (2825.0) (734.5 904.0) (1469.0)
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MAINTENANCE MANUAL
Table 202. Recommended Standard Torques for ShearType Fasteners

Diameter Thread Recommended Maximum Thread Recommended Maximum
inch Size Torque Allowable Size Torque Allowable
(mm) (Fine) in. lb (Nm) in. lb (Nm) (Coarse) in. lb (Nm) in. lb (Nm)
0.1640 79 12 79 12
8 36 8 32
(4.1656) (0.79 1.02) (1.36) (0.79 1.02) (1.36)
0.1900 12 15 25 12 15 21
10 32 10 24
(4.8260) (1.36 1.69) (2.82) (1.36 1.69) (2.37)
0.250 30 40 60 25 30 45
1/4 28 1/4 20
(6.350) (3.39 4.52) (6.78) (2.82 3.39) (5.08)
0.3125 60 85 140 48 55 100
5/16 24 5/16 18
(7.9375) (6.78 9.60) (15.82) (5.42 6.21) (11.30)
0.3750 95 110 240 95 110 170
3/8 24 3/8 16
(9.5250) (10.73 12.43) (27.12) (10.73 12.43) (19.21)
0.4375 270 300 500 140 155 280
7/16 20 7/16 14
(11.1125) (30.51 33.90) (56.49) (15.82 17.51) (31.64)
0.50 290 410 660 240 290 520
1/2 20 1/2 13
(12.70) (32.77 46.32) 74.57) (27.12 32.77) (58.75)
0.5625 480 600 960 300 420 650
9/16 18 9/16 12
(14.2875) (54.23 67.79) (108.47) (33.90 47.45) (73.44)
0.6250 660 780 1400 420 540 900
5/8 18 5/8 11
(15.8750) (74.57 88.13) (158.2) (47.45 61.01) (101.69)
0.750 1300 1500 3000 700 950 1500
3/4 16 3/4 10
(19.050) (146.9 169.5) (339.0) (79.09 107.34) (169.5)
0.8750 1500 1800 4200 1300 1800 2700
7/8 14 7/8 9
(22.2250) (169.5 203.4) (474.6) (146.9 203.4) (305.1)
1.00 2200 3300 6000 2200 3000 4500
1 12 18
(25.40) (248.6 372.9) (678.0) (248.6 339.0) (508.5)
1.1250 3000 4200 9000 3300 4000 7200
11/8 12 11/8 8
(28.5750) (339.0 474.6) (1017.0) (372.9 452.0) (813.6)
1.250 5400 6600 15000 4000 5000 10000
11/4 12 11/4 8
(31.750) (610.2 745.8) (1695.0) (452.0 565.0) (1130.0)
Page 204
Revision 38 201000
MAINTENANCE MANUAL
Table 203. Locking (Drag) Torque for SelfLocking Fasteners

Diameter Thread Maximum Minimum Thread Maximum Minimum
inch Size in. lb in. lb Size in. lb in. lb
(mm) (Fine) (Nm) (Nm) (Coarse) (Nm) (Nm)
0.1640 15 1.50 15 1.50
836 8 32
(4.1656) (1.7) (0.17) (1.7) (0.17)
0.1900 18 2.0 18 2.0
10 32 10 24
(4.8260) (2.03) (0.23) (2.03) (0.23)
0.250 30 3.50 30 4.50
1/4 28 1/4 20
(6.350) (3.39) (0.40) (3.39) (0.51)
0.3125 60 6.50 60 7.50
5/16 24 5/16 18
(7.9375) (6.78) (0.73) (6.78) (0.85)
0.3750 80 9.50 80 12.0
3/8 24 3/8 18
(9.5250) (9.04) (1.07) (9.04) (1.36)
0.4375 100 14.0 100 16.50
7/16 20 7/16 14
(11.1125) (11.3) (1.58) (11.3) (1.86)
0.50 150 18.0 150 24.0
1/2 20 1/2 13
(12.70) (16.95) (2.03) (16.95) (2.71)
0.5625 200 24.0 200 30.0
9/16 18 9/16 12
(14.2875) (22.60) (2.71) (22.60) (3.39)
0.6250 300 32.0 300 40.0
5/8 18 5/8 11
(15.8750) (33.90) (3.62) (33.90) (4.52)
0.750 400 50.0 400 60.0
3/4 16 3/4 10
(19.050) (45.19) (5.65) (45.19) (6.78)
0.8750 600 70.0 600 82.0
7/8 14 7/8 9
(22.2250) (67.79) (7.91) (67.79) (9.27)
1.00 800 90.0 800 110.0
1 12 18
(25.40) (90.39) (10.17) (90.39) (12.43)
1.1250 900 117.0
11/8 12
(28.5750) (101.69) (13.22)
1.250 1000 143.0
11/4 12
(31.750) (112.98) (16.16)
Page 205
201000 Revision 38
MAINTENANCE MANUAL
Page 206
Revision 38 201000
MAINTENANCE MANUAL
Section
202000
Cleaning
MAINTENANCE MANUAL
CLEANING
1. Cleaning 3. Airframe Exterior and Rotor Blades
Cleaning
(Ref. Section 910000) Consumable Materials
Item Nomenclature (Ref. Section 910000)
Item Nomenclature
CM234 Solvent, drycleaning
General cleaning of oil and dirt deposits from Use care to prevent scratching
the helicopter and its components must be CAUTION of aluminum skin when clean-
accomplished by using drycleaning solvent ing main rotor blades. Never use volatile
(CM234), standard commercial grade kerosene solvents or abrasive materials. Never apply
or a solution of detergent soap and water. bending loads to blades or blade tabs during
Exceptions that must be observed are specified cleaning.
in the following cleaning paragraphs.
NOTE: Avoid directing soapy or clean water
concentrations toward engine air intake
Some commercial cleaning area and instrument static source ports in
CAUTION agents, such as readily avail- aft fairing.
able household cleaners, contain chemicals (1). Wash helicopter exterior, including
that can cause corrosive action and/or leave fiberglass components and rotor blades,
residue that can result in corrosion. Exam- when necessary, using solution of clean
ples of cleaning agents that are not to be water and mild soap.
used are Fantastic" and 409" type clean-
ers, or locally made strong soap cleaners. (2). Clean surfaces stained with fuel or oil
by wiping with soft cloth dampened by
2. Fuselage Interior Trim and Upholstery solvent (CM234), followed by washing
Cleaning with clean water and mild soap.
(1). Clean dirt or dust accumulations from (3). Rinse washed areas with water and dry
floors and other metal surfaces with with soft cloth.
vacuum cleaner or small hand brush. 4. Transparent Plastic Cleaning
(2). Sponge soiled upholstery and trim (1). Clean outside surfaces of plastic panels
panels with a mild soap and lukewarm by rinsing with clean water and
water solution. Avoid complete soaking rubbing lightly with palm of hand.
of upholstery and trim panels. Wipe
solution residue from upholstery with (2). Use mild soap and water solution or
cloth dampened by clean water. aircraft type plastic cleaner to remove
oil spots and similar residue.
(3). Remove imbedded grease or dirt from Never attempt to dry plastic
upholstery and carpeting by sponging CAUTION panels with cloth. To do so
or wiping with an upholstery cleaning causes any abrasive particles lying on plas-
solvent recommended for the applica- tic to scratch or dull surface. Wiping with
ble" fabric (nylon, vinyl, leather, etc). dry cloth also builds up an electrostatic
charge that attracts dust particles from air.
NOTE: If necessary, seat upholstery may be
thoroughly drycleaned with solvent. When (3). After dirt is removed from surface of
complete drycleaning is performed, uphol- plastic, rinse with clean water and let
stery must be reflameproofed. airdry or dry with soft, damp chamois.
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202000 Revision 23
MAINTENANCE MANUAL
(4). Clean inside surfaces of plastic panels 6. Cleaning Of Engine Air Inlet Screens
by using aircraft type plastic cleaner
and tissue quality paper wipers. (1). Remove engine air inlet and engine
cooling air screen (Ref. Chap. 71).
5. Engine Compressor Contamination (2). Clean screens with soft brush to remove
Removal dirt accumulations.
(3). Immerse screen in solution of detergent
(Ref. Chap. 71 and the applicable Allison and allow to soak approximately 15
Engine Operation and Maintenance Manual, minutes. Flush out clear water. Allow
Table 201, Sec. 010000) screen to drain and airdry thoroughly.
Page 202
Revision 23 202000
MAINTENANCE MANUAL
Section
203000
Painting
MAINTENANCE MANUAL
PAINTING
1. Paint Finish
Polyurethane paint is used for the helicopter (Ref. Section 910000)
exterior finish. The primary interior finish is Item Nomenclature
acrylic paint. A base coat of primer is used on CM305 Lacquer, acrylic
most helicopter structure. CM318 Primer
CM320 Thinner, lacquer
2. Paint Removal
(1). Apply applicable chemical surface
Consumable Materials treatment (Ref. Sec. 204000) if metal
(Ref. Section 910000) protection is not adequate. If chemical
Item Nomenclature surface treatment is undamaged, or has
already been applied, wipe surface
CM229 Paint remover
clean with thinner (CM320) and wipe
CM230 Paint remover dry immediately.
(2). Apply coat of primer (CM318). Feather
Use paint remover (CM229 or CM230) when it primer coating onto surrounding color
becomes necessary to remove finish paint coat. Allow primer to airdry for 30
coatings. Ordinarily, use of paint remover minutes.
should be limited to stripping of paint from (3). Apply lacquer (CM305) color coats to
parts that require magneticparticle or match original finish color.
fluorescentpenetrant inspection and to parts
that require removal of excessive paint B. Touchup Flaking or Dried Paint or
buildup. When possible, use highpressure Primer
water spray to rinse off paint remover and
paint particles and to neutralize paint Consumable Materials
remover. Solvent type paint remover usually (Ref. Section 910000)
does not remove primer coating; acid type Item Nomenclature
solvent removes primer. CM801 Abrasive paper, silicon carbide
If paint remover is used in vicin-

CAUTION ity of drive shaft couplings, be (1). Sand nonadherent surface to smooth
sure couplings are completely masked and featheredge with surrounding area,
covered. If paint remover contacts coupling using 320grit or finer abrasive paper
diaphragms, rust spots will develop and cou- (CM801), and wet or dry sanding
pling replacement is required. If acid type method. Do not sand beyond point
paint remover is used, comply with all spe- where chemical film protection begins
cial safety precautions listed on container. to show through primer.
(2). Touchup sanded area [Ref. Touchup
3. Paint Touchup Small Sanded Area).
C. Touchup Primer Not Adhering to Metal
Following procedures apply to application of
Finish
both polyurethane and acrylic paints.
A. Touchup Small Sanded Areas Consumable Materials

The following procedure is for rework of Item Nomenclature
scratches, nicks, gouges and other small CM801 Abrasive paper, silicon carbide
blemishes.
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203000 Revision 23
MAINTENANCE MANUAL
(1). Use 320grit or finer abrasive paper (4). Lightly sand surface with 320grit
(CM801) and wet or dry sanding abrasive paper (CM801). Normal grain
method to sand through chemical film appearance does not require further
to bare metal. Feather surrounding filling or sanding.
surface with bare surface.
(5). Apply primer and color finish (CM305)
(2). Retreat bare metal with applicable [Ref. Touchup Small Sanded Areas).
chemical film (Ref. Sec. 204000)
using brush application. E. Touchup Polycarbonate Plastic Parts
(3). Touchup retreated surface [Ref.
Touchup Small Sanded Areas). Consumable Materials
D. Touchup Glass Fiber Laminate Parts Item Nomenclature
CM220 Naphtha aliphatic
CM217 Isopropyl alcohol
Item Nomenclature CM305 Lacquer, acrylic
CM217 Isopropyl alcohol CM317 Resin primer / Thinner
CM219 Methylethylketone
CM305 Lacquer, acrylic (1). Wipe surface clean with a 1:1 mixture
CM316 Epoxy coating / Thinner of naphtha (CM220) and isopropyl
CM801 Abrasive paper, silicon carbide alcohol (CM217). Mix equal parts (1:1)
of primer resin (CM317) and thinner.
Apply one coat to surface and allow to
(1). Remove all gloss from area requiring airdry minimum of 3 hours. Apply
finish with 100grit or coarser abrasive epoxy primer and color finish (CM305)
paper (CM801) until there is a uniform [Ref. Touchup Small Sanded Areas).
dull condition.
F. Touchup ABS Thermoplastic Parts
MEK solvent is flammable.
WARNING Use only in wellventilated
area and away from heat and flame. Consumable Materials
(2). Wipe surface clean with 1:1 mixture of
Item Nomenclature
MEK (CM219) and isopropyl alcohol
(CM217). CM305 Lacquer, acrylic
(3). Squeeze one coat of PolyEP (CM316),

thinned as required with thinner, into Clean surface with mild soap and water. Dry
fiberglass pores until surface of fibers is thoroughly. Apply one coat of lacquer (CM305)
smooth. [Ref. Touchup Small Sanded Areas).
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MAINTENANCE MANUAL
4. Main Rotor Blade Paint

CAUTION
The following procedures is to be used whenev- D When sanding paint from the main rotor
er the main rotor blades require either blade, take care to not damage rivet heads
repainting or paint touchup. and sealant.
D Do not sand through the paint and primer
NOTE: into the base metal.
D Repaint main rotor blades only in sets to (4). Using 320 grit, or finer, abrasive paper
maintain rotor balance. Never completely (CM801) and wet or dry sanding
repaint only one main rotor blade method, sand areas that require
installed on helicopter. painting.
D New main rotor blades have the inboard (5). Using a soft cloth, dampened in
24 inches (610 mm) painted gloss white. isopropyl alcohol (CM217), thoroughly
This aids in inspection of the blade. clean main rotor blade.
D At owneroperators convenience, inser- (6). Inspect sanded areas for damage.
vice main rotor blades may have the in-
board 24 inches (610 mm) painted gloss B. Main Rotor Blade Paint Application
white.
NOTE: If inboard 24 inches (610 mm) of main
rotor blade is to be painted white, paint is to
Consumable Materials be applied to the entire circumference of the
(Ref. Section 910000) blade. There is to be no ridges in the paint
Item Nomenclature when completed.
CM206 Chemical coating (1). Inspect main rotor blade (Ref. Sec.
621000, Main Rotor Blade Inspec-
tion).
CM304 Enamel, epoxy
(2). Ensure all bushings, bearing, data
CM318 Primer
plates and the abrasion strip are
CM729 Tape, masking, pressure sensitive protected from paint with tape
CM801 Abrasive paper, silicon carbide (CM729).
(3). Using a soft cloth, dampened in
isopropyl alcohol (CM217), thoroughly
A. Main Rotor Blade Paint Removal clean main rotor blade.
(1). Position main rotor blade on a bench of (4). Treat any bare metal areas of main
sufficient length to provide support. rotor blade with chemical coating
(CM206).
(2). Inspect main rotor blade (Ref. Sec. NOTE: Mix primer (CM318) according to
621000, Main Rotor Blade Inspec- manufacturers recommendations.
tion).
(5). Allow mixed primer to stand for 15 to
When removing paint from 30 minutes prior to use.
CAUTION main rotor blade, do not use any NOTE:
paint remover. Bonding agents used in
manufacture of the blade may be damaged D Working life of mixed primer is four hours
by the chemicals causing the blade to be un- maximum.
serviceable. D Primer allowed to stand for more than
two hours must be stirred or shaken be-
(3). Apply tape (CM729) to all bushings, fore use.
bearing, data plates and the abrasion D Addition of freshly mixed primer to re-
strip. plenish an older mixture is not permitted.
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203000 Revision 34
MAINTENANCE MANUAL
(6). Apply primer (CM318) to sanded areas, When removing paint from tail
feather into surrounding color coat. CAUTION rotor blade, do not use any paint
remover. Bonding agents used in manufac-
(7). Allow to airdry for one hour minimum. ture of the blade may be damaged by the
chemicals causing the blade to be unservice-
NOTE: Mix paint (CM304) according to able.
manufacturers recommendations.
(2). Apply tape (CM729) to all bushings,
(8). Allow mixed paint to stand for 20
data plates and the abrasion strip.
minutes minimum prior to use.
NOTE: (3). Plug root end of tail rotor blade to
ensure no paint enters.
D Working life of mixed paint is four hours
maximum.
CAUTION
D Addition of freshly mixed primer to re-
plenish an older mixture is not permitted. D When sanding paint from the tail rotor
blade, take care to not damage rivet heads
(9). Apply paint (CM318) to primed areas. and sealant.
Featheredge paint while applying.
D Do not sand through the paint and primer
(10). Allow to airdry for eight hours into the base metal.
minimum.
(4). Using 320 grit, or finer, abrasive paper
(11). Remove protective tape from main rotor (CM801) and wet or dry sanding
blade. method, sand areas that require
painting.
NOTE: Main rotor assembly may need to be re
balanced after painting. (5). Using a soft cloth, dampened in
5. Tail Rotor Blade Paint clean tail rotor blade.
The following procedures is to be used whenev- (6). Inspect sanded areas for damage.
er the tail rotor blades require either repaint-
ing or paint touchup. B. Tail Rotor Blade Paint Application
NOTE: Repaint tail rotor blades only in sets to (1). Inspect tail rotor blade (Ref. Sec.
maintain rotor balance. Never completely 641000, Tail Rotor Blade Inspection).
repaint only one tail rotor blade installed on
helicopter. (2). Ensure all bushings, data plates and
the abrasion strip are protected from
paint with tape (CM729).
(Ref. Section 910000) (3). Ensure root end of tail rotor blade is
Item Nomenclature plugged to prevent entry of paint.
CM206 Chemical coating
CM217 Isopropyl alcohol (4). Using a soft cloth, dampened in
CM304 Enamel, epoxy
clean tail rotor blade.
CM318 Primer
CM729 Tape, masking, pressure sensitive (5). Treat any bare metal areas of tail rotor
CM801 Abrasive paper, silicon carbide blade with chemical coating (CM206).
NOTE: Mix primer (CM318) according to

A. Tail Rotor Blade Paint Removal manufacturers recommendations.
(1). Inspect tail rotor blade (Ref. Sec. (6). Allow mixed primer to stand for 15 to
641000, Tail Rotor Blade Inspection). 30 minutes prior to use.
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Revision 34 203000
MAINTENANCE MANUAL
NOTE: NOTE:
D Working life of mixed primer is four hours D Working life of mixed paint is four hours
maximum. maximum.
D Primer allowed to stand for more than
D Addition of freshly mixed primer to re-
two hours must be stirred or shaken be-
plenish an older mixture is not permitted.
fore use.
D Addition of freshly mixed primer to re- (10). Apply paint (CM318) to primed areas.
plenish an older mixture is not permitted. Featheredge paint while applying.
(7). Apply primer (CM318) to sanded areas,
feather into surrounding color coat. (11). Allow to airdry for eight hours
minimum.
(8). Allow to airdry for one hour minimum.
(12). Remove protective tape from tail rotor
NOTE: Mix paint (CM304) according to
blade.
manufacturers recommendations.
(9). Allow mixed paint to stand for 20 NOTE: Tail rotor assembly may need to be re
minutes minimum prior to use. balanced after painting.
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Revision 34 203000
MAINTENANCE MANUAL
Section
204000
Corrosion
Prevention
MAINTENANCE MANUAL
CORROSION PREVENTION
1. Corrosion Control (1). Coat contacting surfaces with layer of
sealing compound (CM425), in addition
The airframe is fabricated primarily of to primer (CM318).
aluminum and some magnesium alloys, with Do not use steel washers.
selective use of stainless steel and titanium, CAUTION
and should be checked regularly for any signs
of corrosion, especially at points of dissimilar (2). Use 5056S aluminum alloy washers
and overlapping metal contact. Corrosion of under boltheads and nuts that would
dissimilar metals is the result of several otherwise contact magnesium. If 5056S
conditions; lack of sufficient insulation in aluminum is not available, use 5052S
areas of metal contact, tears or punctures in alloy washers.
metal itself, and areas where protective
finishes have been scuffed, scratched, chipped (3). Apply primer on attaching hardware
or worn away. Perform corrosion control before installation.
according to MDHI Corrosion Control Manual
3. Sealing Compound Application
(CSPA3) and instructions in the following
paragraphs. Use sealing compound (CM425) to replace
loose or missing sealant on exterior surfaces.
Do not apply potassium hydrox- Sealant is used to fill seams and joints that
CAUTION ide to or near bolts, fasteners, might trap water. Apply sealant as follows:
seams, or faying surfaces. Immediately af-
ter completing the magnesium and alumi- Consumable Materials
num test (Ref. NOTE below), wash the (Ref. Section 910000)
tested area with water to prevent burns and Item Nomenclature
continued action on the material.
CM425 Sealing compound
NOTE: To differentiate between aluminum and
magnesium alloy, apply one drop of ordinary (1). Check that seam or joint is clean and
potassium hydroxide (dropped from a glass free of foreign matter and moisture.
rod) to the surface of the metal being tested.
If the alloy is aluminum, a foaming or boil- (2). Apply sealant with putty knife or
ing action of the liquid, accompanied by a similar tool.
black discoloration of the metal, will imme- (3). Force sealant well down into seam to
diately occur. If the alloy is magnesium, no eliminate any air pockets.
reaction will be evidenced.
(4). Fillet sealant to give joint or seam a
smooth appearance.
2. Magnesium Alloys Insulation Against
Corrosion 4. Main Rotor Hub Corrosion Prevention
(TriFlow Wash Procedure)
To prevent galvanic corrosion between
magnesium and any dissimilar metals: The following procedure will help prevent
corrosion of main rotor hub components,
especially on helicopters operated in marine
Consumable Materials environments. The procedure should be
(Ref. Section 910000) accomplished following the last flight each day
Item Nomenclature for helicopters operated in marine or other
corrosive environments, and at each 25hour
CM318 Primer inspection (Ref. Chap. 05), or more often if
CM425 Sealing compound desired, for helicopters not operated in
corrosive environments.
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204000 Revision 23
MAINTENANCE MANUAL
(5). Wash remainder of helicopter exterior

Consumable Materials using fresh water spray.
Item Nomenclature (6). Wash main rotor blades with Zip Wax
(CM227) or equivalent, mixed per
CM104 Lubricant, spray
manufacturers instructions.
CM227 Washing compound with wax
5. Main Rotor Blades Corrosion Arresting
Use care when working The following procedure will help prevent
WARNING around turning rotor blades. corrosion of main rotor blades. The procedure
Stay low. Remain on right side of heli- should be accomplished following the last
copter to avoid tail rotor blades. flight each day on helicopters operated in
marine or other corrosive environments, and
NOTE: Perform the first step below prior to en- weekly for helicopters not operated in corrosive
gine shutdown, following the last flight of environments.
the day if possible. When the rotor stops
turning, the laminates of the strappack
spread apart slightly. Contaminates col- Consumable Materials
lected on the edges of the strappack assem- (Ref. Section 910000)
bly can enter the area between the lami- Item Nomenclature
nates as they spread apart. If the rotor CM227 Washing compound with wax
continues turning until the contaminants CM228 Surface cleaner
are washed away, centrifugal force will keep
the laminates compressed and not allow the
corrosive substances to enter the area be- Wear rubber gloves when us-
tween the laminates. WARNING ing phosphoric solution in
next step.
(1). Bring engine to ground idle (6465 %
Nl); set SCAV AIR to ON (Ref. applica- (1). Wipe down main rotor blades with
ble PFM, Table 201, Sec. 010000). surface cleaner (CM228).
Perform the following:
(2). Rinse main rotor blades immediately
(a). Spray fine fresh water mist on main with water and dry. (Ref. Sec. 202000
rotor blades. for additional information on cleaning
main rotor blades.)
(b). Direct a strong stream of fresh water
(3). Wax main rotor blades with Zip Wax
into main rotor hub and control
(CM227) or equivalent, mixed per
system at main rotor hub.
(c). Spray entire rotor hub with lubricant A. Main Rotor Blade and Damper Attach
(CM104). Pins Corrosion Prevention
(2). Shut down engine and allow rotor If helicopter is subject to saltladen atmo-
blades stop turning. sphere, lubricate mating surfaces of barrel nut
and cam handle at each periodic inspection,
NOTE: In the next step, spray directly between using corrosion preventive oil (CM120) (Ref.
individual laminates. Chap. 62).
(3). Lift main rotor blades to separate strap

pack laminates and spray strappacks Consumable Materials
with lubricant. (Ref. Section 910000)
Item Nomenclature
(4). Perform engine water wash (Ref. Chap. CM120 Oil, corrosion preventive
71).
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MAINTENANCE MANUAL
6. Magnesium Alloy Exterior Surface (2). Using swab, liberally apply chemical
Touchup Treatment film (CM206). Allow solution to remain
on surface for 1 to 3 minutes, or until
surface becomes amber to brown in
Consumable Materials color.
Item Nomenclature
(3). Rinse treated surface thoroughly with
CM207 Chromic acid solution clean water. After rinsing, wipe off
CM320 Thinner, lacquer excess moisture with clean lintfree
cloth. If dry compressed air is available,
blow any moisture from joints or
(1). Wash affected area with solution of crevices and allow to dry completely at
mild soap and clean fresh water. Rinse room temperature for approximately 1
area with clean water and wipe dry hour.
using clean soft lintfree cloth.
(4). Apply paint finish touchup (Ref. Sec.
(2). Use thinner (CM320) on damaged area 203000).
to remove any grease and old paint.
(3). Apply chromic acid solution (CM207) by 8. Steel Alloy Exterior Surface Touchup
swabbing exposed area for 10 to 30 Treatment
minutes.
(4). Using clean cloth soaked in clean, fresh (Ref. Section 910000)
water, thoroughly rinse area where Item Nomenclature
solution was applied. Allow area to
thoroughly dry. CM228 Surface cleaner
CM801 Abrasive paper, silicon carbide
(5). Apply paint finish touchup (Ref. Sec.
203000).
(1). Remove loose paint and corrosion
7. Aluminum Alloy Exterior Surface Touchup products by scraping area with sharp
Treatment phenolic scraper, brushing with heavy
fiber brush and light sanding with
320grit or finer abrasive paper
Consumable Materials (CM801).
Item Nomenclature
(2). Wash off area with mild soap and clean
CM206 Chemical coating fresh water; rinse thoroughly.
(3). Treat surface with surface cleaner

NOTE: If there is any question of whether or (CM228).
not the protective coating is removed, it
should always be assumed that bare metal
is exposed. (4). Allow solution to remain on surface for
approximately 5 minutes. Keep sur-
(1). Wash affected area with solution of faces wet.
mild soap and fresh water. Rinse area
with clean water and wipe dry with (5). Rinse thoroughly with clean water. Dry
clean soft lintfree cloth. with clean lintfree cloth and then
allow to airdry completely.
NOTE: Avoid letting chemical mixture dry on
surface in next step. If it has dried, rewet (6). Apply paint finish touchup (Ref. Sec.
surface with solution. 203000).
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MAINTENANCE MANUAL
9. Splitter Bungee Spring Corrosion Control (1). After helicopter shutdown, insert
(500N) absorbent cloth into area around
splitter bungee spring.
It is recommended that after shutdown from
the last flight of the day, for helicopters
operating in a corrosive environment, the (2). Liberally spray spring with lubricant
splitter bungee spring be sprayed with (CM104) until spring inner coils are
TriFlow. coated.
(3). Remove absorbant cloth from around
spring.
Item Nomenclature
CM104 Lubricant, spray
(4). Wipe excess spray from aircraft.
Table 201. AntiCorrosion Chemical Finishes Aluminum
Process Applicable Specification Normal Coating Thickness and Color
Dow #1 (Chrome Pickel) MILM3171, Type I Removes metal. Iridescent yellow or red;
gray coatings are unacceptable.
Dow #7 (Dichromate MILM3171, Type III No dimensional change. Wrought or
Treatment) extruded parts chestnut brown; castings
light brown to black; AZ91CT6 and
AZ92AT6 alloys gray.
Dow #17 (Anodize) MILM45202, Type I light coat Class C: 0.00020.0003 inch
(0.005080.00762 mm); light green.
Type II heavy coat Class D: 0.00020.0035 inch
(0.005080.08890 mm); dark green.
Dow #19 (Chromic Acid MILM3171, Type VI No dimensional change; gray to black.
Brushon Treatment)
Page 204
Revision 23 204000
MAINTENANCE MANUAL
Section
209000
Nondestructive
Inspection
MAINTENANCE MANUAL

MAINTENANCE MANUAL
NONDESTRUCTIVE INSPECTION
1. Nondestructive Inspection Methods missing fasteners, security of parts,
corrosion, and damage.
A. Visual Inspection
(3). Treat any corrosion found during
(Ref. Figure 201) preliminary inspection.
(1). Select applicable visual inspection aids (4). Clean the areas or surface of parts to be
from the following list:
inspected.
(a). A flashlight with the correct explo-
sive atmosphere rating, beam spread, (a). Remove any contaminates that
efficiency, and brightness for the might hinder surface indications.
inspection being performed. (b). Do not remove protective finishes.
(b). An inspection mirror on a ball joint
(5). Using optical aids as required, inspect
for use in viewing an area that is not
area as follows:
in the normal line of sight.
(c). A 210 power magnifying glass to (a). Examine surface for cracks using a
expose defects that cannot be seen by flashlight, and confirm with a
the unaided eye. magnifying glass.
(d). A borescope to allow remote visual (b). Examine surface for other disconti-
inspection of internal surfaces or nuities, such as: discoloration from
otherwise inaccessible areas. overheating; buckled, bulging, dented
skin; cracked, chafed, split, or dented
(2). Perform a preliminary inspection of tubing; chafed electrical wiring;
overall general area for cleanliness, delaminating of composites; and
presence of foreign objects, deformed or damaged protective finishes.
EYE ABOVE REFLECTED

LIGHT BEAM
INCANDESCENT
LIGHT BEAM
LINE OF SIGHT
REFLECTED LIGHT BEAM
5 TO 45
FAYING SURFACES CRACK OPEN TO SURFACE G200001
Figure 201. Visual Inspection Technique
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MAINTENANCE MANUAL
B. Dye Penetrant Inspection

Consumable Materials Item Nomenclature
(Ref. Section 910000) CM234 Solvent, drycleaning
Item Nomenclature
The coin tap method of inspection is used
CM805 Dye penetrant kit evaluate composite structures. The coin tap is
limited to detecting shallow defects.
(1). Using cleaning solvent (CM234), clean When inspecting cored structure, two sided
area to be inspected. access is required. When multiple laminates
are installed over core, the core bondline
cannot be evaluated.
NOTE:
The sound of an acceptable part can vary
D Manufacturers instructions on Dye Pene-
considerably and the entire area must be
trant Kit take precedence over the follow-
tapped in order to detect any variance.
ing steps.
Compare the sound of the suspected area with
D Parts to be inspected must be dry and the sound of a known acceptable area.
heated to at least 70F (21.1C) but not
An acceptable area will have a slightly sharper
over 130F (54.4C).
or crisper sounding response. A dead or flat
sound is unacceptable, and requires a more
(2). Apply penetrant from dye penetrant kit thorough type of NDI.
(CM805) by brushing, spraying or by
dipping. Allow to stand for a minimum Any suspect areas must be in-
of 2 minutes. CAUTION spected by person(s) qualified in
the appropriate NDI. Contact MDHI cogni-
(3). Remove excess penetrant with remover zant engineering for recommended NDI pro-
(available with dye penetrant kit cedures and applications.
(CM805)), or by cleaning with plain (1). Thoroughly clean area to be inspected
water. Allow part to dry. with cleaning solvent (CM234).
(4). Apply a light even layer of developer (2). Perform a visual inspection for any
from dye penetrant kit (CM805) by raised or blistered appearing areas.
brushing, spraying or by dipping. When
dipping, avoid excess quantity. NOTE: Tap the entire area to be inspected in-
cluding any surrounding area of like
construction.
(5). Penetrant, which has penetrated into
cracks (or other openings) in the surface (3). Using a coin, light hammer, or other
of the part will be drawn out by the suitable blunt object, lightly tap the
developer resulting in a bright red surface of the part to be inspected.
indication.
D. Fluorescent Penetrant Inspection
(6). If part is serviceable or repairable, Refer to the appropriate manufacturers
clean part free of penetrant and related instructions for type of equipment and
developer with cleaning solvent materials being used.
(CM234).
E. Magnetic Particle Inspection
C. Coin Tap Inspection Refer to the appropriate manufacturers
related instructions for type of equipment and
(Ref. Figure 202) materials being used.
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Revision 40 209000
MAINTENANCE MANUAL
0.25 INCH
(6.35 MM)
2.00 INCH
(50.8 MM)
0.375 INCH
(9.52 MM)
DIA BALL
MATERIAL: MILD STEEL OR BRASS
G200002
Figure 202. Coin Tap Inspection
F. Eddy Current Inspection General (a). Personnel doing nondestructive tests

must be qualified and certified in of
This procedure includes general information NAS 410 or ASNT SNTTC1A or
on material, equipment and procedures for the equivalent. Personnel making must
detection of surface cracks. be certified to Level 2 minimum.
The Eddy Current test instruments induce an
Eddy Current into a conductive medium and (b). The test facilities written procedure
detect the change in the induced eddy current approved by the Level 3 technician
field which is produced by a defect. must be followed.
Related Publications (2). Equipment

(Ref. Section 010000 (Table 201)
Specification Publication Title Refer to equipment manufacturers
NAS410 instructions for type of material
Nondestructive Testing Personnel inspected.
Qualification and Certification
ASNTSNTTC1 (a). Electronic Electronic All electron-
Nondestructive Testing Personnel ic equipment must be calibrated
Qualification and Certification annually or after repair. Records
ASTM E 1316 must be kept and made available
Standard Terminology for Nondestructive when requested. All calibration must
Examinations be made to a national standard. The
equipment must be approved for the
type of part examined. Maintain a
(1). Personnel Qualification and Certifica- 3:1 signal to noise ratio during
tion. inspection.
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209000 Revision 40
MAINTENANCE MANUAL
(b). Probes Must be correct for the part (4). Standardization

shape, depth of penetration, and
frequency range for material ex- (a). Standardization must be done in
amined, and sensitivity to sense the accordance with the manufacture
defect. Test probes must not give recommendations.
interference during movement. (b). Calibration scan must be done
Probes must be identified with the before, during and after the inspec-
manufacturers part number and tion. If the after calibration shows
frequency range. test equipment is not accurate, do a
calibration of the equipment and do
(c). Standards Reference calibration another inspection on all components
standards can be actual parts (with examined since last acceptable
natural defects) or from test blocks. calibration.
All calibration standards must be
calibrated and certified.
1). Reference standards must be of an (5). Regulatory Requirements

alloy of the same base material
The Eddy Current Inspection of
and temper or approximately the
components must be done with the
same electrical conductivity,
test facilities local aviation regulato-
surface texture, shape, and defect
ry authority and approved proce-
location as the part to be in-
dures.
spected.
(6). Test Facilities
2). Only the reference standards
calibrated and certified must be (a). Approved facilities must use the
used for the specific component same or equivalent equipment.
examined. All calibration stan-
dards must be kept to a national (b). Analysis of all indications must be
standard. Records must be kept made in accordance with the test
and made available when reques- facilities approved procedures and
ted. with defects.
(c). Parts with defects must be removed
(3). Surface preparation All surface from service in accordance with the
contamination that could cause an facilities approved procedures.
interference with the inspection must
be removed. Methods of cleaning must (d). Records must be completed in
not damage surface finish or damage to accordance with the facilities ap-
the part. proved procedures.
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Revision 40 209000
MAINTENANCE MANUAL
Chapter
21
Environmental
Control System
MAINTENANCE MANUAL
TABLE OF CONTENTS
211000 Ventilation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Environmental Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Cabin Vent Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cabin Vent Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cabin Vent Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cabin Ventilating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cabin Ventilating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cabin Ventilation Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Cabin Ventilation Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Cabin Ventilating Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Cabin Ventilating Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Cabin Ventilating Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. SnapVent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. SnapVent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. SnapVent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Ventilating System Pointed Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Ventilating System Round Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
214000 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Heating System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Heating System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Troubleshooting Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Heat Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Heat Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Heating Valve and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Heat Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Heat Control Valve Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Heat Control Valve Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Heat Control Valve Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Cabin Heat Control Handle and Diffuser Installation . . . . . . . . . . . . 205
5. Heating System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Heat Control Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Heat Control Valve Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Heating System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Heat Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page i
MAINTENANCE MANUAL

8. Heat Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Heater Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Control Valve Shim Thickness Determination . . . . . . . . . . . . . . . . . . . 208
9. Heating System Muffler and Ducts Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 205. Hose and Ducting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Heating System Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Heating Valve Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Ducting Installation (517) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Ducting Installation (519) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Outlet Installation and Convenience Panel Modification . . . . . . . . . 902
E. Modification of Existing 517 to 519 Configuration . . . . . . . . . . . . . . . . . . . . . . . . 903
F. Ducting Installation (521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
G. Cabin Heat Control Cable Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
H. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Table 901. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902. Engine Air Bleed Line Installation (250C20B) . . . . . . . . . . . . . . . . . 905
Figure 903. Engine Air Bleed Line Installation (250C20R/2) . . . . . . . . . . . . . . . 906
Figure 904. Engine Air Bleed Line Installation (250C30) . . . . . . . . . . . . . . . . . . . 907
Figure 905. Heating Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2) . . . . 909
Page ii
MAINTENANCE MANUAL
Section
211000
Ventilation Systems
MAINTENANCE MANUAL
VENTILATION SYSTEMS
1. Environmental Systems (4). Remove control cable nut from plunger
housing and pull entire control cable
The cabin ventilation system consists of a out aft through instrument panel
ventilation valve, control cable and snapvents mounting hole.
installed in the door windows. The ventilation
valve contains a moveable vane operated by a B. Cabin Vent Control Cable Installation
pushpull cable mounted in the right center of (1). Route replacement control cable
the instrument panel. The control cable locks through instrument panel and secure in
the vane in any selected position, controlling place using lockwasher and control
airflow. Fresh air forced through an opening in cable nut.
the lower front canopy passes through the
valve and is directed into the cabin. (2). Secure control cable sleeve to valve
bracket with clip.
Adjustable snapvents are installed in each
door window. The snapvents can be opened (3). Position shaft arm so that vane assem-
and rotated to face the airstream to supple- bly is fully closed.
ment fresh air intake, or in the trail position, (4). Insert control cable wire through hole
provide a ventair exhaust outlet. in swivel and move control knob to fully
closed position.
Before high speed flight; ensure
CAUTION that all snapvents are posi- (5). Tighten swivel on control cable wire
tioned up, aft or down with outs in the trail and install cotter pin.
position. Door damage and vibrations could
occur if vent cutouts face the airstream. (6). Check swivel for free rotation by
actuating control knob through full
NOTE: stroke. Inspect valve assembly for
complete closure of inlet opening when
D The following maintenance procedures control knob is pushed forward against
cover round or pointed nose helicopters. cable panel fitting stop. Check valve
Whenever reference is given to diffuser door for looseness on shaft and defor-
type valve this is for round nose military mation; valve door must be flat; a firm,
D model, and likewise the Y" type is for snug fit is required in the inlet.
civil models.
(7). Reinstall right side fairing on instru-
D For round nose model with diffuser or Y" ment panel.
type valve, refer to Figure 202. For
pointed nose Y" type valve, refer to 3. Cabin Ventilating Valve Replacement
Figure 201.
A. Cabin Ventilating Valve Removal
2. Cabin Vent Control Cable Replacement (1). Remove left and right side fairing from
instrument panel; then remove ducts
A. Cabin Vent Control Cable Removal from rear of ventilating valve.
(1). Ensure that electrical power is OFF. (2). Actuate control cable to full open
position.
(2). Remove right side fairing from instru- (3). Remove control cable clip and discon-
ment panel. nect control cable from swivel on valve
shaft.
(3). Disconnect control cable from swivel in
valve shaft. Remove clip and separate (4). Drill out rivets and remove valve
control cable from support bracket. assembly from helicopter canopy panel.
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211000 Revision 23
MAINTENANCE MANUAL
B. Cabin Ventilation Valve Installation (3). Position vane assembly on shaft and
secure with screws using loctite
(1). Position ventilating valve on canopy (CM431).
panel and align rivet holes. Attach
valve to canopy panel with rivets (4). Install washer on end of shaft and
spaced at 90 degrees. insert cotter pin.
NOTE: If rivet holes are elongated or oversize, (5). Operate valve several times to assure
install next larger rivets. freedom of operation and positive
closing.
(2). Secure control cable sleeve to valve
bracket with clip. 6. Cabin Ventilating Valve Inspection
(3). Install swivel assembly loosely in arm (1). Inspect for cracks, secure attachment to
of shaft. canopy panel and separation of bonded
joints.
(4). Position shaft arm so that vane assem-
bly is fully closed. NOTE: Very small, widely separated spots or
voids in plastic joints are not separation but
(5). Insert control cable wire into swivel air pockets produced during solvent bonding
assembly and move control knob to at manufacture.
fully closed position.
(2). Inspect for bent shaft or vane assembly
(6). Tighten swivel assembly on control and excessive shaft wear in pivot areas.
cable wire; install cotter pin.
(3). Inspect seal on vane assembly for wear.
(7). Operate valve through several open
close cycles to assure ease of operation 7. Cabin Ventilating Valve Repair
and to determine that valve locks in
any position when control knob is
released. Consumable Materials
(8). Install ducts on rear of valve; then Item Nomenclature
install instrument panel left and right CM418 Cement, epoxy
side fairings.
4. Cabin Ventilation Valve Disassembly (1). Patch polycarbonate valve body cracks
and repair seam separations according
(1). Remove screws and separate vane to repair methods specified for polycar-
assembly from shaft. bonate plastic (Ref. Sec. 203000).
(2). Remove cotter pins and slide shaft from (2). Replace unserviceable seal if installed,
valve body. using cement (CM418) according to
container instructions.
5. Cabin Ventilating Valve Reassembly
8. SnapVent Replacement
A. SnapVent Removal
Item Nomenclature (1). Push snapvent outward in window
CM431 Sealing, locking and retaining compound (open position).
(2). Grasp open side of snapvent and gently
(1). Install cotter pin in hole at control arm squeeze it into an elliptical shape.
end of shaft. Install washer on shaft to
bear on cotter pin. (3). Slip snapvent out of window hole at
about a 30 degree angle to surface of
(2). Insert shaft in body of valve. window.
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Revision 23 211000
MAINTENANCE MANUAL
B. SnapVent Installation (2). Slip snapvent flange into window hole

(1). Hold open end of replacement snapvent at an angle of about 30 degrees to
and gently squeeze it into an elliptical surface of window. Be sure ends of wire
shape. stiffener are inside window pole.
CONTROL KNOB
INSTRUMENT PANEL
CONTROL CABLE NUT

VENT VALVE CONTROL AIR DUCT
CABLE
DOOR WINDOW
SNAP VANT CABIN VENT VALVE
K
BRACKET
CANOPY PANEL
CLIP
SHAFT
OUTSIDE (RAM) AIR IN-

SIDE (EXAUST) AIR RIVET
VANE
SWIVEL ASSEMBLY SEAL
VENTILATING VALE VANE ASSEMBLY
G211001
Figure 201. Ventilating System Pointed Nose
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211000 Revision 23
MAINTENANCE MANUAL
OUTSIDE (RAM) AIR
INSIDE (EXHAUST) AIR
DOOR WINDOW
SNAP VANT
NOTE CONTROL KNOB
CONTROL CABLE NUT
VENT VALVE CONTROL

CABLE
CLIP
AIR DUCT
SWIVEL
ASSEMBLY INSTRUMENT
PANEL
SHAFT
BRACKET
CANOPY PANEL
RIVET
SEAL VANE
VANE ASSEMBLY CABIN VENT VALVE
JAM NUT AND SPRING

LOCKWASHER
CONTROL KNOB
CLIP
CONTROL CABLE
SWIVEL
ASSEMBLY VALVE ASSEMBLY NOTE:
SPRING PIN DEFFUSOR 369D INSTRUMENT PANEL SHOWN,
SHAFT 500MD CONFIGURATION VALVE IS
INSTALLED WITH A TSHAPED
OPEN PANEL.
CANOPY PANEL
COLLAR
VALVE PLATE RIVET
TUBE
G211002
Figure 202. Ventilating System Round Nose
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Revision 23 211000
MAINTENANCE MANUAL
Section
214000
Heating System
MAINTENANCE MANUAL
HEATING SYSTEM
1. Heating System Description and enclosed behind the heating system
Operation access cover. Air is Ducted overhead
from the muffler into the cargo/pas-
(1). The heating system mixes cold air senger and crew compartments. Six
supplied by the oil cooler blower and fanshaped diffusers distribute air
hot air extracted from the engine throughout the cabin.
compressor scroll. Cabin air tempera-
ture is mechanically controlled with a (4). The muffler consists of a laminated
handle in the crew compartment that fiberglass housing, perforated alumi-
positions a cable operated mixing valve. num core, and a one inch layer of
The system distributes temperature fiberglass wool around the core.
controlled air via a muffler and ducts to
strategically located cabin outlets. (5). Air outlets are also provided for the
cargo/passenger compartment through
(2). The heat control valve is mounted on an overhead duct diffuser valve
the forward left side of the firewall mounted in the passenger convenience
bulkhead. The valve consists of a panel. Diffuser valve airflow can be
housing that contains air control ports adjusted as required.
for mixing hot and cold air. A 90 inlet (a). The 519 heating system adds
elbow attaches the valve to the com- ducting to provide two floorheated
pressor bleed air tube through the air outlets.
firewall bulkhead. The valve housing
inlet contains a stainless steel bleed air (b). The 521 heating system provides
flow control ball valve that is rotated by ducting for one floorheated air
an attached drive pulley. A nozzle on outlet.
the inlet body injects hot air down-
stream of cold air. A fitting supports the (6). The control handle, control cable and
cold air control vane and drive pulley conduit assembly are incorporated in
that is rotated by a drive belt. Hot air is the left side of the duct attached to the
mixed with cold air at a variable ratio. overhead canopy structure. Moving the
Because engine bleed air temperature control handle forward opens the heat
is approximately 500F (260C), cold air control valve. Control handle travel is
is never completely shut off while the approximately 23/4 inches (6.985 cm)
system is in use. from open to closed. Cable routing is
along the left side of the main rotor
(3). The duct system and the direct air flow mast support structure and down to the
muffler are forward of the firewall and firewall mounted control valve.
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214000 Revision 23
MAINTENANCE MANUAL
2. Heating System Fault Isolation

(Ref. Table 201)
Table 201. Troubleshooting Heating System

Symptom Probable Trouble Corrective Action
Actuation of heat valve control Control valve pulley drive belt Replace faulty parts and adjust
lever produces no heated air at broken valve.
outlets
Pulley shaft retaining pin sheared Replace faulty parts and adjust
or control cable spring pin sheared valve.
Heat valve ball binding in housing Shim between valve housing and
elbow fitting.
Heat control valve internally Replace valve.

defective
Heat control clevis improperly Adjust control cable clevis.

adjusted for length
Cracked, broken or disconnected Replace defective ducts.

ducting in system
Movement of heat valve does not Same troubles as above Replace faulty parts and adjust
shut off hot air valve.
Movement of heat valve control Control cable crushed or one or Check cable operation with clevis
lever very difficult more routing bend radii less than 3 detached from pulley arm.
inch (7.62 cm) minimum
Heat valve control lever does not Cable sleeve (sheath) damage Replace defective parts.
remain in selected position causing preload springback
Air excessively hot at diffusers (*) Improper cold air mixing Adjust valve.
(*) CAUTION: Do not operate engine until this condition is corrected. Canopy plastic or ducting may be badly
damaged if operation is continued.
3. Heat Control Valve Replacement (4). In left side of engine compartment,

disconnect the hot bleed air line at the
(Ref. Figure 201) heat control valve elbow fitting.
A. Heat Control Valve Removal (5). Loosen the elbow tube nut and remove
elbow fitting and gasket.
(1). Remove interior trim and left aft (6). Remove hardware attaching the upper
bulkhead access cover. and lower end of control valve assembly
to the canted firewall.
(2). Remove cotter pin, washer, and pin
attaching clevis to heat control valve. (7). Remove clamp securing cool air duct to
valve.
(3). If particle separator is installed, loosen
and back off tube coupling nut of (8). Remove attaching hardware connecting
369H9014951 tube assembly at end the muffler and valve. Remove heat
connected to elbow assembly. control valve and gasket.
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Revision 23 214000
MAINTENANCE MANUAL
STRAP
GROMMET (TYP)
CABLE
AFT AIR DUCTS
FWD AIR DUCTS
AIR DIFFUSERS
AIR DIFFUSERS
MUFFLER
BOLT
INDEX FOR COLD AIR COLD AIR
VANE ALIGNMENT IN CONNECTOR HOSE
OPEN POSITION
CABLE ASSEMBLY
GASKET
CLAMP
WASHER
NUT
CLAMP
SPACER
NUT CONTROL VALVE

WASHER ASSEMBLY
ROTATED
BOLT NOTE
1/8 IN. (3.175MM) DRILL
JAM NUT
RIGGING PIN HOLES
(OPEN POSITION)
NOTE:
GASKET COTTER
INSTALLED ON AIRCRAFT WITH
PIN
AIR PARTICLE SEPARATOR. NUT
NUT CLEVIS
BLEED AIR LINE WASHER BLEED AIR
PIN
FITTING
ELBOW BOLT
G214001A
Figure 201. Heating Valve and Cable Installation
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214000 Revision 23
MAINTENANCE MANUAL
B. Heat Control Valve Installation 4. Heat Control Valve Cable Replacement

(Ref. Figure 202)
(Ref. Section 910000) A. Heat Control Valve Cable Removal
Item Nomenclature
(1). Remove left half of engine air inlet
CM113 Antiseize compound low temperature forward fairing, interior trim and left
aft bulkhead access cover.
(1). Install control valve assembly on (2). Remove seven screws attaching heat
forward left side of firewall with bolts, duct outer box to heat duct and canopy
washers and nuts, but do not tighten. frame.
NOTE: Use antiseize compound (CM113) on (3). Remove clamps, straps, and grommets
threaded fittings. that attach cable to structure along its
full length. Remove cotter pin and
(2). For helicopters equipped with particle clevis pin from clevis at heater control
separator kit, reengage tube coupling valve arm.
nut of the 369H9014951 tube assem-
bly with elbow assembly, and tighten B. Heat Control Valve Cable Installation
fasteners.
(3). In left side of engine compartment, (Ref. Section 910000)
install elbow, nut and new gasket. Item Nomenclature
Tighten retaining hardware on heating
CM430 Sealant, solvent resistant
valve.
(4). Connect control valve flange to muffler, (1). Route the cable assembly into position.
using new gasket and four nuts, Check that grommet is in place on
washers, and bolts. cable.
(5). Install cool air connector hose on (2). Install clamps and straps that attach
control valve inlet and secure with cable to structure. Install grommet at
clamps. structure fairing that cable passes
through using adhesive (CM430).
(6). Position control handle fully forward.
Position lever on control valve to open, NOTE: The clamp nearest to the valve should
and insert a 1/8 inch (3.175 mm) not be tightened until after travel is
rigging pin through lever and into valve checked.
boss.
(3). Attach heat duct outer box to heat duct
(7). Loosen jam nut on control cable and and canopy frame with seven screws.
adjust clevis so attach holes align with
(4). For adjustment of clevis refer to initial
hole in valve lever. Install pin through
installation.
clevis and valve lever, and safety with
cotter pin. (5). When assured that cable will operate
the valve freely through full range of
(8). Tighten clevis jam nut. Remove rigging travel, tighten the clamp nearest the
pin from valve lever. valve.
(9). Move control handle full aft and (6). Reinstall aft bulkhead access cover,
forward several times to check ease of interior trim, and left half of engine
heat control operation. inlet fairing.
(10). Reinstall left aft bulkhead cover and (7). After installation, adjust handle to be
interior trim. parallel to windshield glass.
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Revision 23 214000
MAINTENANCE MANUAL
CANOPY FRAME
CANOPY CENTER
RIGID TUBING
FRAME TRIM AND
SPRING PLUNGER HEAT DUCT LOWER
CABLE SUPPORT BLOCK

(3 PLCS) (NOTE)
SET SCREW 2 PLCS

CONTROL HANDLE
WASHER
(NOTE)
HANDLE SHAFT
HEAT DUCT/TRIM OUTER BOX

6 PLCS
CANOPY CLIP DIFFUSER
INCREASE HEAT
ASSEMBLY
HEAT DUCT MOUNTING
SCREW
CONTROL HANDLE DIFFUSER ASSEMBLY
INSTALLATION INSTALLATION
NOTE:
INSTALL WASHERS AS REQUIRED TO
OBTAIN DIFFUSERTODUCT FIT
G214002
Figure 202. Cabin Heat Control Handle and Diffuser Installation

5. Heating System Inspection (f). Inspect rubber hose for tears and
evidence of deterioration.
(Ref. Figure 202)
(g). Inspect all ducts and muffler for
(1). With the helicopter on the ground, security of attachment and coupling
perform the following: hardware and any duct section or
muffler damage that would allow
(a). Inspect heat valve control lever and heated air leaks. Inspect diffuser
cable for freedom of operation. outlets for condition of cemented
joints or distribution ducts.
(b). Remove interior trim and left aft
bulkhead access cover in cargo (h). In engine compartment, inspect tube
compartment. Inspect cable for connecting engine air bleed fitting to
condition and security. control valve for cracks and security
of hex nuts.
(c). Inspect cable clevis for security of
jam nut and cotter pin. (2). Perform an operational check (Ref.
Heating System Operational Check).
(d). Inspect security of heat control valve
A. Heat Control Valve Inspection
to firewall; check pulley belt for
condition. (1). Inspect timing belt for deterioration,
stretching, worn teeth, or evidence of
(e). Inspect flexible fiberglass hose for slipping.
tears and deformation due to failure
of inner supporting wire or short (2). Inspect valve housing for deep dents
radius bends. and cracks, mating flanges and connect-
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214000 Revision 23
MAINTENANCE MANUAL
ing area for bends or dents which would (2). Remove hardware (nut, washer, bolt)
prevent tight connections, bearing attaching elbow to valve housing and
bosses for galling and excessive wear, remove elbow and shims if installed.
and interior seat and ball valve for
galling. (3). The Oring, wave washer, retainer, ball
valve and coupling are now free for
(3). Inspect pulley shafts for galling and removal.
evidence of wear.
(4). Inspect ball valve and retainer for (4). Cut lockwire and remove three screws
cracks, galling and evidence of wear; from valve lever and drive pulley.
cold air vane for flatness and evidence Remove timing belt.
of excessive edge wear.
(5). Remove pin from drive pulley. Remove
B. Heat Control Valve Cable Inspection shaft from valve housing; inner and
outer washers will fall free.
(1). Inspect cables for kinks, crushed sleeve,
and corrosion. (6). Remove screws attaching cold air valve
vane to shaft. Remove plate spring and
(2). Clean all corrosion from cable. spacers. Remove vane.
(3). If cable is kinked or crushed, locate
problem and repair or replace cable as (7). Remove pulley, shaft, and washers from
required. valve housing.
6. Heating System Operational Check (8). Remove pin from driven pulley to
complete disassembly.
(1). Perform an operational check of the
heating system as follows: 8. Heat Control Valve Repair
(2). Move CABIN HEAT control handle full
forward to open heat valve. Control (1). Repair small dents in valve housing by
handle should not creep away from ON bumping out and burnishing. Repair
position. warped flanges by straightening on a
surface plate. No weld repairs are
(3). Remove left aft bulkhead access cover. permitted.
(4). Check that valve is full open position by (2). No repairs are permitted on moving
inserting a 1/8 inch (3.175 mm) drill parts, ball valve, retainer, coupling, or
shank (or rod) into the drive pulley shafts which are cracked, bent or badly
alignment hole (Ref. Figure 201). The worn.
drill shank should pass through the
pulley and enter a mating alignment (3). Place valve housing upside down on a
hole in the valve housing inlet body. suitable workbench (Ref. Figure 204).
Find the thickness of shims required
(5). Check the cold air vane drive pulley between valve body and elbow fittings
alignment mark. The mark should align as follows.
with a similar mark on the cold air
vane housing.
(a). Measure diameter of the ball valve
using an outside micrometer. Record
7. Heat Control Valve Disassembly
as dimension A.
(Ref. Figure 203)
(b). Place ball valve in housing and use a
(1). Rotate ball valve lever fully counter- depth micrometer to measure dis-
clockwise to position the ball valve tance from housing flange to top of
open. ball. Record as dimension B.
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Revision 23 214000
MAINTENANCE MANUAL
VANE
SCREW
SPACER
SPRING
SHAFT
HOUSING
PIN
WASHER
DRIVEN PULLEY
BOLT
WASHER
WASHER DRIVE PULLEY
BELT
BLEED AIR
FITTING
ROTATED SHIM (AR)

(NOTE) SCREW
PIN
BALL
RETAINER
WASHER
LEVER
WASHER
NUT
COUPLING
SHAFT
WASHER
ORING ELBOW
NOTE:
USED ON AIRCRAFT WITH
PARTICLE SEPARATOR.
G214003
Figure 203. Heater Control Valve Assembly
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214000 Revision 23
MAINTENANCE MANUAL
(c). Multiply dimension A by 0.933; then position ball valve in housing to engage
subtract the result from 1.627 in. coupling (ball valve in open position).
(4.1356 cm). Record as dimension C.
(6). Install new Oring in elbow flange
Example: groove.
Ball dia. A = 1.441 in. (3.6601 cm)
(7). Install retainer and washer in housing
1.441 in. (3.6601 cm) x 0.933 = 1.344 on ball valve.
in. (3.4138 cm)
NOTE: A 1/2 inch (12.7 mm) wood dowel may
1.627 1.344 in. (3.4138 cm) = 0.283 be inserted through top of assembly to tem-
in. (7.1882 mm) (dim. C) porarily hold these parts in position.
(d). Compare dimension B with dimen-
(8). Install shim(s) of thickness determined
sion C. If B is greater than C, no
in above steps; then install elbow on
shims are required. If C is greater
valve housing flange with four bolts
than B, add shims 369H8007 until B
and nuts. Washers are installed under
is equal to or greater, 0.010 in. (0.254
both the bolt head and the nut. Use
mm) max., than C.
care to avoid nicking or cutting the
Example: Oring during mating.
B = 0.270 in. (6.858 mm) and C = The flanges of the valve housing
0.283 in. (7.1882 mm) CAUTION and elbow should mate without
the use of undue force. If flanges do not mate
(e). Add a 0.015 in. (0.381 mm) shim to easily, the internal parts of the valve may be
dimension B. B now equals 0.285 in. misaligned. Investigate before tightening
(7.239 mm), or 0.002 in. (0.0508 mm) bolts.
more than dimension C, and is a
correct total shim thickness for use. (9). Install washer and ball valve so that
(4). Install washer (Ref. Figure 203) on ball rigging pin holes in pulley and in valve
valve shaft; then insert this assembly housing boss are aligned (ball valve in
into valve housing boss. open position).
(5). Install coupling on shaft (check that the (10). Install pin through ball valve pulley
ball drive lug is chamfered); then and shaft.
DEPTH MICROMETER
DIMENSION B (FLANGETOBALL)
VALVE HOUSING
NOTE:
FIND DIMENSION C AS FOLLOWS:
DIMENSION A (BALL DIAMETER) C = 1.627 IN. (4.1356 CM) A X 0.993).
REFER TO TEXT FOR USAGE.
BALL VALVE
BALL VALVE SUPPORT
G214004A
Figure 204. Control Valve Shim Thickness Determination
Page 208
Revision 27 214000
MAINTENANCE MANUAL
(11). Remove wood dowel if used to align (20). Reinstall and actuator belt pulley on
internal parts; then rotate pulley ball valve using three screws (Ref.
through full travel several times to Figure 201). Note that the screw
assure ease of operation and positive located 180 degrees from the rigging
closing of ball valve. A valve torque pinhole is 1/8 inch (3.175 mm) longer
check, step (18). below, is made after than the others. Remove rigging pin
the timing belt is installed. installed in step (10). above. Safety
screws to each other with lockwire.
(12). Install cold air pulley and washer on
shaft. 9. Heating System Muffler and Ducts Repair
(13). Install cold air pulley and shaft assem-
bly into valve housing. Consumable Materials
(14). Attach cold air vane to shaft using two Item Nomenclature
screws. CM432 Dichloromethane
(15). Rotate ball valve pulley fully counter CM433 Ethylene chloride
clockwise to full stop.
(16). Rotate cold air pulley so that the vane Repair of heat system ducting will depend
is 45 degrees from fully closed, or align upon the type of material used in the section
yellow rigging marks, if present. that requires repair. Rubber hose or flexible
fiberglass hose that is torn, flattened, or
(17). Install a serviceable timing belt deteriorated must be replaced. When removing
between pulleys while maintaining ducting for repair or replacement, use illustra-
valve position located in steps (15).and tion as a guide (Ref. Figure 205).
(16). above.
(1). Repair rigid fiberglass or muffler
(18). Check valve operation by applying 6 according to the fiberglass repair
11 inchounces (0.0423 0.0777 Nm) procedures outlined in the SRM, except
of torque on the ball valve shaft. If the use fireretardant resin.
ball valve does not operate within this
range, change thickness of shims (2). Repair rigid polycarbonate plastic
between the valve elbow and housing as sections by bonding a patch according
required. Shims are provided inch 0.015 to the criteria and methods specified for
inch (0.381 mm), 0.010 in. (0.254 mm), acrylic plastic in FAA AC 43.131A,
and 0.005 inch (0.127 mm) thicknesses. Aircraft Inspection and Repair. Use
dichloromethane (CM432) or ethylene
NOTE: Final total shim thickness should not dichloride (CM433) as the bonding
exceed dimension C (step (c).) by more than agent.
0.10 inch (2.54 mm).
(3). Repair small areas of rib or seam
(19). If rigging marks have not been applied, separation in plastic sections by
paint a yellow index mark, 1/16 inch injecting ethylene dichloride (CM433)
(1.59 mm) wide, on pulley and housing into the void area and clamping
(Ref. Figure 201). together under light pressure.
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214000 Revision 37
MAINTENANCE MANUAL
NOTES:
1. REMOVE ADHESIVE BACKING COVER AND INSTALL PADS
WHERE INTERFERENCE MAY EXIST BETWEEN HOSE
AND STRUCTURE.
DIFFUSER 2. INSURE THAT HEATER HOSE DOES NOT CONTACT OIL
ASSEMBLY FLEX LINES OR STRUCTURE.
SCOTCH FOAM PAD

GROMMET
OIL FLEX LINE
(NOTE 2)
HOSE
DUCT
GROMMET
STANDOFF
CLAMP CLAMP
DUCT ASSEMBLY
MUFFLER
COLD AIR MANIFOLD
COLD AIR HOSE
CONVENIENCE PANEL
CLAMP
DUCTING INSTALLATION
HEATING VALVE
G214005
Figure 205. Hose and Ducting Installation
Page 210
Revision 23 214000
MAINTENANCE MANUAL
HEATING SYSTEM
INITIAL INSTALLATION
1. Heating System Initial Installation assembly (Sta. 31.50); retain washers
for use when installing diffuser assem-
Procedures in this section may be performed at blies.
the operators discretion and are applicable to
369D/E/FF model helicopters. (4). Remove attaching hardware and outer
box from heat duct and canopy frame.
A. Preparation for Installation
(5). Remove rubber plug from left side of
convenience panel.
(Ref. Section 910000) (6). Remove cap from cool air manifold duct.
Item Nomenclature
B. Heating Valve Initial Installation
CM702 Lockwire CRES
(1). Using hardware, install heating valve,
but do not tighten.
(1). Remove engine (Ref. Chap. 71).
(2). On aircraft equipped with engine air
(a). 250C20B 250C20R/2: (Ref. particle separator only, engage tube
Figure 902 or Figure 903) coupling nut of 369H9014951 tube
1). Remove existing plugs and install assembly and tighten fasteners.
tee and elbow. (3). Install elbow, nut and gasket from aft
Tee and elbow must be installed side of firewall. Tighten heating valve
CAUTION so that no interference will exist attaching hardware.
between hose assembly and existing bleed (4). Reinstall engine (Ref. Chap. 71).
air tube.
(a). 250C20B 250C20R/2: (Ref.
2). Install hose assembly and tube Figure 902 or Figure 903)
assembly. Do not reinstall engine
at this time. 1). Connect tube assembly to elbow
using nut and gasket. Torque both
(b). 250C30: (Ref. Figure 904) connecting nuts onto tube assem-
bly to 350 inchpounds (39.54
1). Remove existing plate and install Nm).
fitting, using engine supplied
washers and bolts. Safety with (b). 250C30: (Ref. Figure 904)
lockwire (CM702).
1). Connect engine bleed assembly to
2). Install engine bleed assembly to elbow. Torque connecting nut to
fitting, and secure tube assembly 350 inchpounds (39.54 Nm).
by connecting one end of the strap
to the inlet bell with bolt, nut and C. Ducting Installation (517)
washers, but do not tighten. Attach
clamp to bleed assembly. Secure to (Ref. Figure 906)
strap with attaching hardware.
Tighten nut. Consumable Materials
(2). Remove interior trim panels and aft Item Nomenclature
bulkhead access.
CM411 Adhesive, epoxy
(3). Remove left and right hand guide CM821 Gasket material
assemblies from forward end of duct
Page 901
214000 Revision 23
MAINTENANCE MANUAL
(1). Using clamps, install air hose between NOTE: Ensure that heater hose does not con-
heating valve and cold air manifold tact transmission oil lines or structure.
duct (Ref. Figure 905).
(8). Install aft valve assembly (23) in
(2). Install muffler assembly with gasket convenience panel (24) and connect
and hardware; attach hose to muffler valve to duct (3) with hose (25) and
with clamp. clamps (26).
(3). Remove protective cap from existing (9). Install diffuser assemblies (Ref.
duct assembly (1). Install grommets (2) Figure 202); add washers as necessary
with cement (CM411) to prevent to obtain diffuser to duct fit.
chafing.
D. Ducting Installation (519)
(4). Route heater hose (9) and secure to oil
flex line (10) with clamps (11, 12), (Ref. Figure 906)
bracket (13), and attaching hardware
(14, 15, and 16).
(5). Position standoff (17) on inboard side of (Ref. Section 910000)
channel (18) as shown. Drill two #40 Item Nomenclature
holes and deburr. Attach standoff to
CM318 Primer
channel using two rivets (19).
CM702 Lockwire CRES
(6). Install clamp (20) around hose and
secure to standoff, using attaching
hardware (21 and 22). Install Scotch (1). Perform installation as described (Ref.
Foam (CM821) as required to prevent Ducting Installation (517), steps (1).
chafing. thru (4). and (6).) except that duct (27),
replaces duct (3) and that hose (5) is not
(7). Connect duct (3) to duct assembly (1), secured to duct (27) at this time.
and hose (5). Attach duct (3) to bulk-
head using attaching hardware (6, 7, (2). Install splitter duct (28) with attaching
and 8). Attach hose (5) to duct with hardware (29, 30) and valve (23) into
clamp (4). convenience panel (24).
369D2924791 OUTLET
INSTALLATION SAME
FOR 369D2924792
0.188 IN. (4.7752 MM)
HOLE IN PANEL
NAS14022 SCREW REIDENTIFY AS 369H900205
NAS1329A0875 RIVNUT 369A25443 CONVENIENCE PANEL, TO BE
FITTING AN9608 WASHER
NAS14022 SCREW (OPPOSITE SIDE) MADE FROM 369D2655321 PANEL
AN9608 WASHER
PICK UP EXISTING RIVET 0.40 IN. (10.16 MM)
LOCATION 1.00 IN.
TRUE HOLE LOCATION (2.54 CM)
1.38 IN. (3.5052 CM) 0.30 IN.

(7.62 MM)
2.75 IN. (6.985 CM)
DRILL 0.0200.023 IN. 369D292480
(0.5080.584 MM) HOLE SPLITTER DUCT
NAS13034 BOLT
MS210423 NUT
AN960KD10 WASHER
PICK UP EXISTING
RIVET LOCATION
G214006A
Figure 901. Outlet Installation and Convenience Panel Modification
Page 902
Revision 23 214000
MAINTENANCE MANUAL
(3). Attach hose (25) to valve (23) with F. Ducting Installation (521)
clamp (26), and hose (31) to splitter
duct (28) with lockwire (CM702). (Ref. Figure 906)
(4). Attach hose (25) to lower outlet on duct Consumable Materials

(27) with clamp (26), and second hose (Ref. Section 910000)
(31) to upper outlet on duct (27) with Item Nomenclature
lockwire. CM318 Primer
(5). Mount convenience panel (24) with

attached duct, valve, and hose to (1). Perform installation as described (Ref.
bulkhead with with attaching hardware Ducting Installation (519), steps (1).
(32, 33). thru (5). except replace splitter duct
(28) with duct (43) (Ref. Figure 905).
(6). Measure distance between splitter duct
outlets. Using this dimension, position (2). Position duct (35) and outlet duct (36)
ducts (34, 35) and outlet ducts (36) on bulkhead. Match drill three
parallel to each other on bulkhead. 0.2210.226 inch (5.61345.7404 mm)
Match drill six 0.2210.226 inch holes common to clips into bulkhead.
(5.61345.7404 mm) holes common to Remove outlet duct (36) and duct (35).
duct clips to bulkhead. Remove ducts. Deburr and apply primer (CM318) to
Deburr and apply primer (CM318) to bare metal surfaces. Install rivnuts
bare metal surfaces. Install rivnuts (37).
(37). Reconnect ducts (34, 35) to splitter (3). Connect duct (43) to duct (35) and
duct (28) and attach ducts to bulkhead secure to bulkhead and convenience
with screws (38) and washers (39). panel with attaching hardware (29, 30,
38, 39, 40, 41, and 42).
(7). Install outlets (36) on ducts (34, 35).
Match drill holes through outlet duct (4). Attach hose (5) to duct (27) with clamp
clips into bulkhead (Ref. Figure 901). (4).
Remove outlets. Deburr and apply
primer to bare metal. Install rivnuts G. Cabin Heat Control Cable Initial
(37) were applicable. Install outlets Installation
with attaching hardware (38, 39, 40, 41,
(Ref. Figure 201)
and 42).
(8). Attach hose (5) to duct (27) with clamp Consumable Materials
(4). (Ref. Section 910000)
Item Nomenclature
E. Modification of Existing 517 to 519 CM425 Sealing compound
Configuration
(Ref. Figure 906) (1). Remove clevis and jam nut assembly;
install grommet on cable, remove
(1). The 517 heating system may be existing plug button in canted frame
modified by replacing duct (3) with duct structure, and route cable through hole
(27), modifying the convenience panel, in structure and hole in structure
as illustrated, and by installing addi- fairing.
tional hose (31), splitter duct (28), ducts (2). Remove clamps from duct assembly and
(34 and 35), outlets (36), and associated secure control handle and rigid portion
hardware. of control cable assembly with clamps.
(2). Follow installation instructions (Ref. (3). Tie control cable to existing tubing and
Ducting Installation (519). cables with straps.
Page 903
214000 Revision 23
MAINTENANCE MANUAL
(4). Secure grommet in structure and seal (c). Tighten clevis jam nut. Remove
hole at structure fairing that cable rigging pin from valve lever.
passes through, using adhesive
(CM425). (d). Move pilots heat control handle full
aft and forward several times to
(5). Secure lower end of cable assembly to
check ease of heat control operation.
structure with clamp and attaching
hardware.
(e). Tighten clamp nearest clevis end of
NOTE: Do not tighten clamp until after travel control cable.
is checked.
(f). Reinstall aft bulkhead access cover,
(6). Install heat duct outer box to heat duct
interior trim, and left half of engine
and canopy frame with seven screws.
inlet fairing.
(7). Install jam nut and clevis as follows;
(g). After installation, adjust control
(a). Position heat control handle full handle to be parallel with windshield
forward. Position lever on heat glass.
control valve to open and insert a 1/8
inch (0.125 mm) rigging pin through
H. Weight and Balance
lever and valve boss.
(b). Loosen jam nut on control cable and Weight and balance changes resulting from
adjust clevis so attach holes align installation of heating system equipment are
with hole in valve lever. Install pin listed in Table 901. After installation of
through clevis and valve lever. Install heating system equipment, incorporate
washer and secure pin with cotter changes in helicopter weight and balance
pin. record (Ref. Sec. 081000).
Table 901. Weight and Balance Data
Weight Arm Moment
Configuration
Pounds (kg) Inches (cm) inlb (kg cm)
369H90020517
Added +8.2 (+3.719) 106.7 (271.02) +874.9 (+1007.990)
Removed 0.0
Change +8.2 (+3.719) 106.7 (271.02) +874.9 (+1007.990)
369H90020519
Added +8.6 (+3.901) 110.1 (27965) +946.9 (+1090.942)
Removed 0.0
Change +8.6 (+3.901) 110.1 (27965) +946.9 (+1090.942)
Page 904
Revision 23 214000
MAINTENANCE MANUAL
TEE
(NOTE)
HOSE ASSEMBLY
NUT
TUBE ASSEMBLY
GASKET
ROTATED
GASKET
NUT
HOSE ASSEMBLY
ELBOW
(NOTE)
NOTE:
INSTALL TEE AND ELBOW SO NO INTERFERENCE
OCCURS BETWEEN HOSE ASSEMBLY AND EXISTING
ENGINE BLEED AIR TUBE. G214007
Figure 902. Engine Air Bleed Line Installation (250C20B)
Page 905
214000 Revision 23
MAINTENANCE MANUAL
TEE
NUT
GASKET
GASKET
NUT
NOTE:
INSTALL TEE AND ELBOW SO NO INTERFERENCE
OCCURS BETWEEN HOSE ASSEMBLY AND EXISTING
ENGINE BLEED AIR TUBE.
HOSE ASSEMBLY
ELBOW
(NOTE) G214008
Figure 903. Engine Air Bleed Line Installation (250C20R/2)
Page 906
Revision 23 214000
MAINTENANCE MANUAL
BOLT
(NOTE)
FITTING
ENGINE BLEED
ASSEMBLY
NOTE:
REPLACE EXISTING NUT AND BOLT WITH
NAS1351C0810 BOLT,
MS21043C8 NUT AND
AN9608L WASHER (2 REQD). G214009
Figure 904. Engine Air Bleed Line Installation (250C30)
Page 907
214000 Revision 23
MAINTENANCE MANUAL
HOSE
GROMMET
CLAMP
MUFFLER
COLD AIR HOSE
CLAMP
BOLT
NUT
GASKET
CLAMP
WASHER
NUT HEATING VALVE
WASHER
BOLT
G214010
Figure 905. Heating Valve Installation
Page 908
Revision 23 214000
MAINTENANCE MANUAL
8
5
7 4
517 (REF)
27
14
11
15
21
22 15 10
16
15
14
13
9
20 19 17
16
SCOTCH FOAM 15
12
18
G214011
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2)
Page 909
214000 Revision 23
MAINTENANCE MANUAL
3
32
33
31
27
28
25
26
26
24 37
43
42
30 41
42
39 41
23
38 37
42
29
41
40
35
36
39
38
36
36
41
40
G274012
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 2 of 2)
Page 910
Revision 23 214000
MAINTENANCE MANUAL
Legend (Ref. Figure 906)

1. DUCT ASSEMBLY 23. AFT VALVE ASSEMBLY
2. GROMMET 24. CONVENIENCE PANEL
3. DUCT 25. HOSE
4. CLAMP 26. CLAMP
5. HOSE 27. DUCT
6. BOLT 28. SPLITTER DUCT
7. WASHER 29. SCREW
8. NUT 30. WASHER
9. HEATER HOSE
31. HOSE
10. OIL FLEX LINE
32. SCREW
11. CLAMP
33. WASHER
12. CLAMP
34. DUCT
13. BRACKET
35. DUCT
14. BOLT
15. WASHER 36. OUTLET
16. NUT 37. RIVNUT
17. STANDOFF 38. SCREW
18. CHANNEL 39. WASHER
19. RIVET 40. BOLT
20. CLAMP 41. WASHER
21. BOLT 42. NUT
22. WASHER 43. DUCT

214000 Revision 23
MAINTENANCE MANUAL
Chapter
25
Equipment/
Furnishings
MAINTENANCE MANUAL
TABLE OF CONTENTS
250000 Equipment/ Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Interior Furnishings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Upholstered Seat Furnishings Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Mesh Seat Furnishings Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Crew Upholstered Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Crew Mesh Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Passenger Upholstered Bench Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Mid Bench Seat (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Upholstered Passenger Individual Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
H. Passenger Mesh Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
I. Seat Belts and Shoulder Harnesses (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . 2
J. Seat Belts and Shoulder Harness (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
L. Floor Trim and Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
M. Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
251000 Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Upholstered Crew Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Upholstered Passenger Aft Bench Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Mid Bench Seat Assembly Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Mid Bench Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Mid Bench Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Upholstered Passenger Individual Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Upholstered Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Upholstered Seat Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Upholstered Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Optional Mid Business Seat Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Business Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Business Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Upholstered Seat Installation (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Upholstered Seat Installation (369E/FF 500/600N) . . . . . . . . . . . . 204
Figure 203. Mid and Aft Seating Configuration (600N) . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. Mid and Aft Bench Seat Assembly Installation (600N) . . . . . . . . . . . 206
Figure 205. Upholstered Passenger Individual Seat Installation (369D) . . . . . . 207
Figure 206. MidCabin Business Seat Installation (600N) . . . . . . . . . . . . . . . . . . . 208
Page i
MAINTENANCE MANUAL

251500 Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Crew/Passenger Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Crew Mesh Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Passenger Mesh Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Passenger Mesh Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Crew Mesh Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Passenger Mesh Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Mesh Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Passenger Individual Mesh Seat Adjustment and Storage . . . . . . . 203
7. Mesh Seats Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8. Mesh Seats Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Passenger Bench Mesh Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . 204
1. Mesh Seat Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Model Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Passenger Compartment Bench Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Passenger Compartment Individual Seat Installation . . . . . . . . . . . . . . . . . . . . . . . 901
F. Crew Compartment Mesh Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
G. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
H. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
252000 Seat Belts/Inertia Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Seat Belts/Inertia Reel Description and Operation (369D/E/FF 500N) . . . . . . . . 201
2. Seat Belts/Inertia Reel Description and Operation (600N) . . . . . . . . . . . . . . . . . . . . . 201
3. Crew Seat Belt/Harness Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Seat Belt/Inertia Reel Replacement (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Seat Belt/Inertia Reel Installation (Sam Browne Style)
(369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Seat Belt/Inertia Reel Installation (Yoke Style) (369D) . . . . . . . . . . . 203
Figure 203. Seat Belt/Inertia Reel Installation (Yoke Style)
(369E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Crew Seat Belt/Harness Replacement With Manual Lock Option
(369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Page ii
MAINTENANCE MANUAL

Figure 204. Webbed Shoulder Harness and Seat Belt Installation with Manual
Inertia Reel Lock (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 205. Crew Inertia Reel Installation with Manual Inertia Reel Lock
(369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Seat Belt/Inertia Reel Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Seat Belt/Inertia Reel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Seat Belt/Inertia Reel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9. Seat Belt/Restraint Harness, Crew Seat, Replacement (600N) . . . . . . . . . . . . . . . . . 207
A. Seat Belt/Restraint Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Seat Belt/Restraint Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 206. Seat Belt/Restraint Harness Installation, Crew Seat (600N) . . . . . 207
10. Seat Belt/Restraint Harness, Mid Passenger Seat, Replacement (600N) . . . . . . . . 208
11. Seat Belt/Restraint Harness, Aft Passenger Seat, Replacement (600N) . . . . . . . . . 208
Figure 207. Seat Belt/Restraint Harness Installation, Passenger
Seats (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Comfort Clip Installation and Decal Application (369D/E/FF 500N) . . . . . . . . . . 210
Figure 208. Comfort Clip Installation and Crew Compartment Decal
Application (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 209. Comfort Clip Decal Application Passenger Compartment
(369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
252100 Seating/Belts (Four on the Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Seating/Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Seating/Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Seating/Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Seating/Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Seating/Belt Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Seating/Belt Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Seating/Belts (Four on the Floor) Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Removal of Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Seating and Belts Installation General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
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D. Cant. Sta. 78.50 Brackets, Fittings and Restraint Panels Installation . . . . . . . . 901
Figure 901. Restraint Panel Assemblies and Hardware Installation
(369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 902. Restraint Panel Assemblies and Hardware Installation
(369E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
E. Seat Assemblies Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
F. Aft Seat Belt Assemblies and Shoulder Straps Installation . . . . . . . . . . . . . . . . . . 905
G. Forward Seat Belt Assemblies and Shoulder Straps Installation . . . . . . . . . . . . . 905
Figure 903. Seat Belt and Seat Assemblies Installation
(369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 904. Shoulder Straps and Fittings Installation
(369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
253000 Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cyclic Stick Control Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Copilots Inboard Collective Pitch Stick Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Interior Trim Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cyclic Stick Control Cover Replacement (L/H Command) . . . . . . . . . . . . . . . . . . . . 201
B. Copilots Collective Pitch Stick Cover Replacement (L/H Command) . . . . . . . . . . 201
Figure 201. Crew Compartment Interior Trim (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 202
Figure 202. Passenger Compartment Interior Trim (Sheet 1 of 2) . . . . . . . . . . . . 204
C. Inboard Collective Pitch Stick Cover Replacement (R/H Command) . . . . . . . . . . 206
D. Transmission Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
E. Log Book Holder (Optional for R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
F. Carpeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3. Interior Trim Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Interior Trim Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Crew and Passenger Compartment Interior Trim R/H Command
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Interior Trim and Carpeting General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5. Boltaron Trim Panels Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Fiberglass Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 204. Floor Trim and Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Solvent Bonding Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Epoxy Adhesive Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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Figure 205. Boltaron Panel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
D. Bond and Rivet Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
254000 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Crew Compartment Miscellaneous Furnishings Replacement . . . . . . . . . . . . . . . . . . 201
A. Stowage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Heat Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Foot Rest (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Ash Receiver and Cigarette Lighter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Passenger Compartment Miscellaneous Furnishings Replacement . . . . . . . . . . . . . 201
A. Convenience Panel Replacement (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Passenger Step Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Passenger Step Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Passenger Step Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Passenger Step Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Passenger Step Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Passenger Step Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Miscellaneous Furnishings Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Miscellaneous Furnishings Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Miscellaneous Furnishings (369D) (Sheet 1 of 2) . . . . . . . . . . . . . . . . 203
Figure 202. Miscellaneous Furnishings (369E/FF 500/600N)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Passenger Step Assembly (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
255000 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Cargo Hook Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Cargo Hook Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3. Cargo Hook Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . 102
Table 102. Wire Chart, 369D/E/FF Right or Left Hand Command. . . . . . . . . . . . 102
Table 103. Wire Chart, 369E/FF TPanel with Center Electrical Console,
R/H Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 101. Cargo Hook Wiring Diagrams (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 104
1. Cargo Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cargo Hook Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
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B. Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Manual Release Cable Routing Interior . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Manual Release Cable and Electrical Wire Harness Routing
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403. Cargo Hook Electrical Equipment Installation . . . . . . . . . . . . . . . . . . 405
Figure 404. Hook and Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 405. Cargo Hook Manual Release Lever Installation . . . . . . . . . . . . . . . 407
Figure 406. Cargo Hook Release for 600N Helicopters . . . . . . . . . . . . . . . . . . . . . . 408
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Cargo Hook Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Exterior Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Interior Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
1. Cargo Hook Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Modification of Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Cargo Hook Provisions Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Electrical Components and Wiring Installation (Left and Right Hand
Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Table 901. Cargo Hook Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Fuselage Skin Cutouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
F. Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902. Relay and Bracket Installation Pilots Floor (369D/E/FF) . . . . . . . . . 905
Table 902. VNE Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
G. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Table 903. Cargo Hook Switch Installations Stick Grip . . . . . . . . . . . . . . . . . . . . 906
256000 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Emergency First Aid Kit Contents Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
256300 Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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Figure 201. Hoist System Components (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 202
2. Preparation for Hoisting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3. Hoist System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4. Cyclic Stick Grip and Cyclic Stick Cable Cutter Switch (S600) Replacement . . . . . 208
5. Hoist Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Hoist Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Hoist Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Passenger/Cargo Door Retainer Installation . . . . . . . . . . . . . . . . . . . . 209
6. Winch Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
A. Winch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Swivel Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Cable Cutter Replacement (GuillotineType) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7. Hoist System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8. Hoist Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Table 201. Troubleshooting Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 204. Wiring Diagram Hoist System (L/H Command) . . . . . . . . . . . . . . . 214
Figure 205. Wiring Diagram Hoist System (R/H Command) . . . . . . . . . . . . . . . 215
Figure 206. Schematic Diagram Hoist System Winch . . . . . . . . . . . . . . . . . . . . . 216
1. Hoist Passenger/Cargo Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Helicopter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Electrical Equipment Installation (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Helicopter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
E. Electrical Equipment Installation (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . 904
F. Passenger/Cargo Door Retainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Figure 902. Passenger/Cargo Door Retainer Tube Installation . . . . . . . . . . . . . . . 907
G. Hoist Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
H. Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
I. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
J. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
Figure 903. Cable Antichafing Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
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MAINTENANCE MANUAL

Page viii
MAINTENANCE MANUAL
Section
250000
Equipment/
Furnishings
MAINTENANCE MANUAL
EQUIPMENT/FURNISHINGS
1. Interior Furnishings Description D. Crew Mesh Seating
Standard furnishings on the 369D/E/FF The crew compartment is equipped with

500/600N Helicopters include seats in the crew twopart seats. Each twopart seat consists of
and passenger compartments, seat belts, a seat back and a seat bottom constructed of
interior trim, floor trim and covering, and aluminum tubing frames with a nylon mesh
other miscellaneous furnishing items. covering and rubber pads cemented to the
frame mounting plates. The seat backs are
A. Upholstered Seat Furnishings mounted on the Station 78.50 canted frame.
Configuration Seat bottoms are secured on top of the pilots
seat structure.
The helicopters are equipped with the basic E. Passenger Upholstered Bench Seating
interior furnishings configuration. This
includes upholstered seats with a bench type Passenger compartment seating is provided by
in the passenger compartment and three a bench type tubular steel structure furnished
individual seats in the crew compartment. The with upholstered cushions. The bench seat is
center crew seat is removed for the dual adjustable fore and aft as well as up and down,
controls option. Seat belts are provided at all and may be folded or quickly removed when
seat locations. Interior trim finish is provided cargo space is required. All seat cushions are
throughout interior cabin enclosure. either upholstered and trimmed with vinyl, or
may be all vinyl. Velcro strip fasteners secure
The 600N helicopter comes equipped with a seat cushions in place.
mid position bench seat. At this position in the F. Mid Bench Seat (600N)
passenger compartment, the mid seat can be
positioned in either the forward or aft facing The mid bench seat provides additional three
configuration. abreast seating in the passenger area. This
seat can be positioned in either the forward or
B. Mesh Seat Furnishings Configuration aft facing configuration. The seat belt/harness
system is completely attached to the seat
The helicopters are equipped with a basic structure for quick removal and installation of
interior furnishings configuration. This the entire bench seat assembly.
includes two mesh seats and seat backs in the G. Upholstered Passenger Individual Seat
crew compartment and two stowable mesh
seats in the passenger/cargo compartment. Individual seat installations are also available
Seat belts are provided at all seat locations. for the passenger compartment. The seat
Interior trim is provided for the passenger frames are secured to the bulkhead attach
convenience panel, transmission, passenger aft fittings with balllock pins. When each seat is
bulkhead, inboard collective pitch stick, and folded, the flat surface of the seat back serves
cyclic controls. as a barrier for cargo. Ref. P/N 369D290037 in
the optional equipment list for a further
C. Crew Upholstered Seating description of individual passenger seat
installations (Ref. Table 202, Sec. 0100).
The crew compartment on all models with H. Passenger Mesh Seating
single controls has a threeplace seating
arrangement. A twoplace seating arrange- Two passenger seats are installed in the aft
ment is provided for optional dual controls. compartment of the helicopter. The seats are of
Crew compartment seats consist of left and welded tubular aluminum structure with
right side seat cushions and, if applicable, a nylon mesh covers. The seats may be folded for
center seat cushion. Each seat has a seat back clear cargo space and, if desired, are easily
cushion. Crew compartment seat structure is removed by means of quick disconnect
an integral part of the helicopter fuselage. attachments.
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MAINTENANCE MANUAL
I. Seat Belts and Shoulder Harnesses K. Interior Trim

(369D/E/FF 500N)
Interior trim used in the crew compartment
In the standard installation, Sam Browne type and the passenger compartment is of thermo-
seat belts with shoulder harness straps are plastic material contoured to cover interior
installed at each seat position. Seat belts and structure. Trim panels and covers provide
shoulder straps are fabricated from nylon interior finish, compartment insulation and
webbing with sewnin buckles and attach mounting surfaces for convenience items, and
fittings. Lengths of seat belts and shoulder certain optional equipment. Trim panels and
straps are not adjustable. Inertia reels are covers are attached with Velcro fasteners and
provided to take up slack and allow free with upholstery screws with rivnuts or isolator
movement of the seat occupant. nut mounts on the fuselage structure.
Comfort clips are available for helicopters
equipped with Sam Browne type seat belt L. Floor Trim and Covering
assemblies. The comfort clip is designed to
maintain proper strap tension and relieve Interior floor trim and covering consists of
excessive pressure of the inertia reel shoulder fireresistant carpeting and two foot fairing
harness on the crew or passengers during trim assemblies. The lower part of Sta. 78.50
flight. bulkhead and access doors are also covered
with fireresistant carpeting.
After each seat belt and shoulder harness
assembly is fastened and adjusted for individu- M. Miscellaneous Furnishings
al comfort and safety, the comfort clip is moved
from its original position next to the buckle Miscellaneous furnishings include a stowage
and relocated by sliding up on the harness compartment, heat duct, VNE card holder, foot
strap as close as possible to the inertia reel. rest assembly, helicopter checklist, operational
The clip prevents any further retraction of the record holder, ashtrays, and LH/RH passenger
strap into the inertia reel, thus keeping a step assemblies. The stowage compartment is
constant yet comfortable tension of the under the right floor access door (Ref. Sec.
harness strap against the user. After each 5250). The compartment has a uniformlydis-
flight, the comfort clip is to be returned to its tributed load capacity of 50 pounds maximum
original location. when optional avionics equipment is not
J. Seat Belts and Shoulder Harness (600N) installed in the crew area underfloor compart-
ment. The heat duct provides interior trim for
The crew seats in the helicopter utilize a the canopy frame and mounting surface for the
fourpoint restraint harness that combines the magnetic compass (Ref. Sec. 9520). The VNE
lap seat belts with double shoulder straps for card holder is located on the left side of the
greater occupant security and comfort. Both instrument panel. The helicopter checklist is
mid and aft passenger seats are equipped with stored with the magnetic compass card in the
a threepoint restraint system. The lap seat map case. The operational record holder is
belt and shoulder strap are joined at the end attached to the outboard side of the right
into a single unit for ease of attachment and instrument panel fairing. Ashtrays and
convenience. In one motion, the lap and cigarette lighters are provided in the lower
shoulder belts together can be attached to the portion of the instrument panel and on the
seat buckle. All seat belt/harness systems are back side of the station 78.50 canted bulkhead.
equipped with an automatic locking inertia The removable passenger steps are attached to
reel mechanism. the helicopter side jacking points.
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MAINTENANCE MANUAL
Section
251000
Upholstered Seats
MAINTENANCE MANUAL
UPHOLSTERED SEATS
1. Upholstered Crew Seat Replacement A. Mid Bench Seat Removal
(Ref. Figure 201, Figure 202 and Figure 204) (1). Remove quick release pins that attach
Upholstered Seats for the 369D/E/FF seat support fittings to floor rails.
500/600N Helicopters are the same. The (2). Remove seat assembly.
addition of the mid position bench seat is
unique to the Model 600N. B. Mid Bench Seat Installation
(1). Clear seats of seat belts and shoulder (1). Install seat assembly in aircraft.
straps.
(2). Align seat support fittings with floor
(2). Lift seat cushions away from fuselage rails.
seat structure to release Velcro strip (3). Install quick release pins to secure seat
and fasteners. assembly to floor.
(3). To replace, position seat cushions so 4. Upholstered Passenger Individual Seat
that Velcro fastener strips mate. Apply Replacement
slight pressure to secure seat cushions
in place. (Ref. Figure 205)
(1). Clear seat of seat belts and shoulder
2. Upholstered Passenger Aft Bench Seat straps.
Replacement
(2). Remove balllock pins from bulkhead
(Ref. Figure 201 or Figure 202) attach fittings.
(1). Clear seats of seat belts and shoulder (3). To replace, position seats so that
straps. quickdisconnect pins align with
bulkhead attach points and lock seats
(2). Release seat quickdisconnect fittings in place.
at bulkhead, then at floor points.
5. Upholstered Seat Inspection
NOTE: For height adjustment, install balllock
pins in desired position at support legs and (Ref. Figure 201, Figure 202 and Figure 204)
bulkhead fittings. For fore and aft adjust- (1). Inspect upholstery material for cuts,
ment, move and secure seat back at desired loose stitching or other unserviceable
position on lower frame. condition.
(3). To replace, position bench seat so that (2). Inspect Velcro fastener strips for
quickdisconnect fittings align with security of attachment and condition.
floor and bulkhead attach points.
(3). On passenger seat structure, inspect
(4). Lock seat in place, first at floor fittings quickdisconnect mechanisms for
then at bulkhead fittings. proper operation or damage that may
prevent positive locking.
3. Mid Bench Seat Assembly Replacement A. Upholstered Seat Cleaning
(600N)
(Ref. Sec. 202000, Fuselage Interior Trim
(Ref. Figure 204) and Upholstery Cleaning)
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MAINTENANCE MANUAL
6. Upholstered Seat Repair adjustable seats attached through four seat

tracks that allow seat location adjustment over
a 10 inch span when seats are facing forward.
(Ref. Section 910000) NOTE:
Item Nomenclature
D With the seats in the full aft position and
facing forward, the rear passenger seats
CM405 Adhesive become unusable for passenger seating.
D The seats are removable and may be
(1). Lapstitch frayed or worn upholstery. placed in the aft facing position.
MEK solvent is flammable. D In the aft facing position, only two seat
WARNING Use only in wellventilated locations are available.
area and away from heat and flame.
A. Business Seat Removal
NOTE: Loosened Velcro strips may be reacti-
vated for adhesion by wiping original adhe- (1). Remove quick release pins that attach
sive film with MEK (CM219). seat support fittings to floor rails.
(2). Replace unserviceable Velcro fastener (2). Remove seat assembly.

strips. Install new Velcro strips to mate.
Bond in place with adhesive (CM405). B. Business Seat Installation
(3). Make welded or riveted sleevetype (1). Install seat on tracks with forward
repairs on tubular structure according guide pin in track cutout first.
to FAA AC 43.131A, Aircraft Inspec-
tion and Repair. (2). Once seat guide pin is in track, slide
seat forward until 2 rear guide pins are
7. Optional Mid Business Seat Replacement in the track cutouts.
(600N)
(3). When installing seat facing aft, tilt
(Ref. Figure 206) This option replaces the seatback full forward during
standard mid bench seat with two fore and aft installation.
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MAINTENANCE MANUAL
SEAT BACK CUSHION
SEAT BACK
NOTE 1
AFT SUPORT FIT-

TING AND HEIGHT
ADJUSTMENT
VELCRO STRIP FASTENER
(TYP)
PASSENGER COMPARTMENT
SEAT BOTTOM
CUSHION
LOWER FRAME NYLON

MESH FORE AND AFT
NOTE 2 ADJUSTMENT RELEASE PIN
HOLES
FLOOR STRUCTURE
SUPPORT LEG AND
SEAT BACK HEIGHT ADJUSTMENT
CUSHION
HIGH SHOULDER BEAM
NOTE 1

(TYP)
NOTES:
1. SHOWN WITHOUT CUSHION
FOR CLARITY.
2. CENTER CUSHIONS AND SEAT
SEAT BOTTOM BELTS ONLY FOR 3PLACE
CUSHION
SEATING.
SEAT STRUCTURE
CREW COMPARTMENT
G251000
Figure 201. Upholstered Seat Installation (369D)
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MAINTENANCE MANUAL
SEAT BACK CUSHION

(TYP)
CUSHION SUPPORT
AFT SUPPORT FITTING

AND HIGHT ADJUSTMENT
SEAT BOTTOM CUSHION
SEAT BACK
CUSHION
FLOOR STRUCTURE
LOWER FRAME
LOCKPIN
RELEASE PIN SUP-
SEAT BOTTOM PORT LEG AND
CUSHION HEIGHT ADJUSTMENT
LOW SHOULDER BEAM

(TYP)
SEAT STRUCTURE
CREW COMPARTMENT
G251001
Figure 202. Upholstered Seat Installation (369E/FF 500/600N)
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MAINTENANCE MANUAL
FWD FACING
AFT FACING
OPTIONAL MIDCABIN BENCH SEAT ORIENTATION
6G25069
Figure 203. Mid and Aft Seating Configuration (600N)
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MAINTENANCE MANUAL
QUICK RELEASE PIN

WITH LANYARD (6 PL)
FORWARD, MID AND AFT
ATTACHMENTS ARE TYPICAL
MID BENCH SEAT ATTACHMENT
BALL LOCK PIN
AFT SUPPORT FITTING AND

HEIGHT ADJUSTMENT
FORE AND AFT
ADJUSTMENT HOLES
FLOOR STRUCTURE
SUPPORT LEG AND HEIGHT

ADJUSTMENT
AFT BENCH SEAT ATTACHMENT
BALL LOCK PIN
NOTE: SEAT SHOWN WITH CUSHIONS REMOVED

RELEASE PIN
6G25061
Figure 204. Mid and Aft Bench Seat Assembly Installation (600N)
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MAINTENANCE MANUAL
SEAT BACK
ASSY
SEAT BACK CUSHION
VINYL END PIECES

(TYP)
FABRIC SEAT BOTTOM CUSHION
SEAT BOTTOM
ASSY
SEAT STRUCTURE
UPPER SURFACE
OF FLOOR TOP OF CARPET
VINYL END PIECES

(TYP)
SEATSERECTED POSITION
SEAT FOLDED POSITION SEAT FOLDED POSITION

RH. SIDE L.H. SIDE
G251002
Figure 205. Upholstered Passenger Individual Seat Installation (369D)
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MAINTENANCE MANUAL
RELEASE PIN AND

SEAT TRACK STOP
AFT
MID
FWD
NOTE: PASSENGER RE-

STRAINT NOT SHOWN
RELEASE PIN AND SEAT

TRACK STOP POSITION
FORWARD FACING SEAT

MID: NORMAL POSITION FOR FWD FACING SEAT.
AFT: USED WHEN THE REARMOST SEAT POSITION IS DESIRED.
AFT FACING SEAT
FWD: NORMAL POSITION FOR AFT FACING SEAT.
FOLDUP
ARM REST
SEAT BACK
ADJUSTMENT
HANDLE
OUTER SEAT TRACK
INNER SEAT TRACK
REAR GUIDE PINS
FORWARD GUIDE PIN
FORE AND AFT SEAT AD- TRACK CUTOUT

JUSTMENT HANDLE (HAN-
DLE SHOWN RAISED)
G251006
Figure 206. MidCabin Business Seat Installation (600N)
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MAINTENANCE MANUAL
Section
251500
Mesh Seats
MAINTENANCE MANUAL
MESH SEATS
1. Crew/Passenger Mesh Seats (5). Insert vertical legs into floor structure
and secure.
(Ref. Figure 201 thru Figure 203) The typical
mesh seat installation consists of lightweight (6). If removed, reinstall seat belts and
nylon meshcovered seats installed in the crew shoulder harness.
and passenger compartments. For description
of the various installations, consult the 4. Passenger Mesh Seat Adjustment
Optional Equipment List (Ref. Table 202, (1). (Ref. Figure 203) The height of the
010000). Some installations have a bench bench seat may be adjusted by install-
type passenger seat, some have individual ing the ball lock pins in any of the three
passenger seats, and others have no passenger holes in the vertical support legs, and
seats at all. Installations differ depending on by installing the ball lock pins that
whether the helicopter has a high shoulder support the horizontal legs in any of the
beam or a low shoulder beam, and various seat three holes in each aft support fitting.
colors.
(2). For the fore and aft adjustment of the
2. Crew Mesh Seat Replacement bench seat, insert the seat back legs
into either pair of holes in the seat
(Ref. Figure 201) frame.
NOTE: Identify and retain all components and (3). (Ref. Figure 202) The height of the
hardware removed from the helicopter. individual seats may be adjusted by
inserting lock pins into any of three
(1). Remove or clear area of seat belts and pairs of holes in the aft support fittings
shoulder straps. to secure the horizontal legs of the seat.
(2). Remove installing hardware and lift (4). The individual seats may be folded up
seat bottoms and seat backs from the out of the way to permit cargo storage
helicopter. by first releasing the quickdisconnects
at the forward legs and folding the legs
(3). To replace, install seat backs and seat aft. The seat back is then folded
bottoms with attaching hardware. forward at the upper hinge point. As
the seat is swung up at the aft fitting,
(4). When removed, reinstall seat belt and
the seat back and the seat bottom are
shoulder harness.
rotated forward and down at the lower
hinge point.
3. Passenger Mesh Seat Replacement
5. Crew Mesh Seat Inspection
(Ref. Figure 202 or Figure 203)
(1). Inspect upholstery material for cuts or
NOTE: Identify and retain all components and other unserviceable conditions.
hardware removed from helicopter.
(2). Check rubber pads cemented to each
(1). Remove or clear area of seat belts and mounting plate.
shoulder straps.
6. Passenger Mesh Seat Inspection
(2). Release seat quickdisconnects at aft
fittings, then at floor points. (1). Inspect upholstery material for cuts or
other unserviceable conditions.
(3). Lift seats from helicopter.
(2). Inspect quickdisconnect mechanisms
(4). To replace, attach horizontal support for proper operation and for damage
legs to aft attach fittings with lockpins. that may prevent positive locking.
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MAINTENANCE MANUAL
CREW SEATS BACK CREW SEATS BACK UPPER

LOWER LEGS LEGS, HIGH SHOULDER BEAM
(NOTE)
CREW SEATS FORWARD

LOWER LEGS
INDIVIDUAL
PASSENGER
HIGH SHOULDER BEAM SEATS
MODEL 369D WITH HIGH SHOULDER BEAM SHOWN

CREW SEAT FORWARD
LOWER INBOARD LEG
(LEFT)
NOTE: FASTENER ORIENTATION IS VERTICAL

FOR LOW SHOULDER BEAM INSTALLATION.
G251003
Figure 201. Mesh Seat Installation
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MAINTENANCE MANUAL
NYLON MESH
SEAT BACK
(FOLDS FORWARD)
AFT SEAT
SEAT FITTING AND
SEAT BOTTOM HEIGHT ADJUSTMENT
(FOLDS FOR STOWAGE)
UPPER HINGE POINT
LOWER HINGE POINT
QUICK DISCONNECT
(AT REAR OF LEGS)
PASSENGER INDIVIDUAL MESH SEAT HEIGHT ADJUSTMENT
FOLDING SEAT BACK AND LEGS SEAT STOWAGE
G251004
Figure 202. Passenger Individual Mesh Seat Adjustment and Storage
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MAINTENANCE MANUAL
7. Mesh Seats Cleaning (1). Lap stitch frayed or torn nylon web-
bing, or replace if damaged beyond
(Ref. Sec. 202000, Fuselage Interior Trim repair.
and Upholstery Cleaning)
(2). Install new rubber pads.
8. Mesh Seats Repair
(3). Clean seat mounting plate with clean
cloth dampened with solvent (CM234).
(Ref. Section 910000) (4). Apply cement (CM405) and attach pad
Item Nomenclature to seat mounting plate.
CM234 Solvent, drycleaning (5). Replace damaged nutplates.
CM405 Adhesive
(6). Weld repairs may be performed accord-
ing to FAA AC 43.131A, Aircraft
Repair of seats is limited to the following: Inspection and Repair.
SEAT BACK
FRAME AFT SUPPORT FITTING

AND HEIGHT ADJUSTMENT
FLOOR STRUCTURE
NYLON MESH
BALLLOCK PIN
FORE AND AFT AD-
JUSTMENT HOLES SUPPORT LEG AND
HEIGHT ADJUSTMENT
RELEASE PIN
G251005
Figure 203. Passenger Bench Mesh Seat Adjustment
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MAINTENANCE MANUAL
MESH SEATS
1. Mesh Seat Initial Installation (2). Install ball lock pins.
Procedures in this section are for initial (3). With release pins raised and locked,
installation of 369H90040BSC, 501, and insert the two vertical legs into keyhole
503 mesh seat installations on Model 369D fitting slots in floor.
helicopters with to replace the existing cushion
seats. NOTE: For height adjustment, install ball lock
fittings in any of the three attachment
A. Model Applicability holes, in the vertical support legs, and in the
aft support fittings. For fore and aft adjust-
To determine the applicability of the mesh seat ment, insert the seat back lower legs in ei-
installation for use on each model helicopter, ther pair of holes in lower frame.
consult the Optional Equipment List (Ref.
Table 202, 010000). (4). Move vertical support legs to right in
keyhole fittings and unlock release pins
B. Preparation for Installation in legs. The pins will drop to bottom of
slots and secure support legs to fittings
(1). Check all electrical switches for OFF in floor.
position. Ensure that BATTERYOFF
EXT switch is OFF. E. Passenger Compartment Individual Seat
Installation
(2). Identify all components and hardware
to be removed for access to work areas. (Ref. Figure 202)
Protect components from damage and
foreign matter until reinstalled. NOTE: Installation procedures for left and
right seats are identical.
C. Helicopter Equipment Removal
(1). Position passenger seat horizontal
Prior to installing the mesh seats, a limited support legs in aft support fittings.
number of items must be removed from the
helicopter to accommodate seat installation. (2). Install ball lockpins.
(3). Depress pushbutton quick disconnects
(1). Clear seats of seat belts and shoulder
at front legs of seat.
straps.
(4). Insert legs into keyhole fittings in floor.
(2). Lift crew compartment seat cushions
Move legs outboard and release push-
away from fuselage seat structure to
buttons to secure legs in place.
release Velcro strips and fasteners.
Remove seats from helicopter (Ref. Sec. F. Crew Compartment Mesh Seat
251000). Installation
(3). In passenger compartment, release (Ref. Figure 201) Installation includes
existing seat quickdisconnect fittings installing a shim under the inboard forward
at aft bulkhead, then at floor points. leg of the left crew seat.
Remove existing installed seats from
helicopter. (1). Position mesh seat back halves in crew
compartment.
D. Passenger Compartment Bench Seat
Installation (2). Attach upper ends of seat backs to
canted stations with screws and
(Ref. Figure 203) washers.
(1). Position bench seat horizontal support (3). Attach lower legs to helicopter seat
legs in aft support fittings. structure with screws.
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MAINTENANCE MANUAL
(4). Position lower halves of mesh seats on (1). Install seat belts and shoulder harness
helicopter seat structure. in crew compartment (Ref. Sec.
252000, Seat Belt/Inertia Reel
(5). Insert shim under inboard forward leg Replacement).
of left seat. Attach leg to seat structure
with bolt and washer. (2). Install seat belts and shoulder harness
(6). Attach remaining forward legs of seats in passenger compartment.
to seat structure with bolts and wash- H. Weight and Balance Data
ers.
G. Helicopter Equipment Installation Weight and balance data resulting from BSC,
501 and 503 mesh seat installations are
After installation of mesh seats, a limited listed in Table 901. After installation, incorpo-
number of items must be replaced in the rate changes in helicopter weight and balance
helicopter. records (Ref. Sec. 081000).

Weight Arm Moment
Configuration
BSC Installation +20.80 (+9.435) 99.7 (253.24) +2074 (+2389.5)

501 Installation +20.35 (+9.231) 99.6 (252.98) +2027 (+2335.3)
503 Installation +20.80 (+9.435) 99.7 (253.24) +2074 (+2389.5)
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MAINTENANCE MANUAL
Section
252000
Seat Belts/Inertia
Reel
MAINTENANCE MANUAL
SEAT BELTS/INERTIA REEL

1. Seat Belts/Inertia Reel Description and shoulder strap are joined at the end into a
Operation (369D/E/FF 500N) single unit for ease of attachment and conve-
nience. In one motion, the lap and shoulder
Inertia reeltype seat belt/harness equipment belts together can be attached to the seat
consists of a shoulder harness, an inertia reel, buckle.
and a twopiece adjustable seat belt for both
the pilot and copilot. 3. Crew Seat Belt/Harness Cleaning
The shoulder harnesses and seat belts are of The harness and seat belt may be cleaned
nylon web material with sewnin length using a softbristle brush and a mild solution
adjusters and end adapters for attachment of of warm water and laundry detergent.
the harnesses to the seat belts. Inertia reels,
furnished as part of the harnesses, are 4. Seat Belt/Inertia Reel Replacement
mounted on the Sta. 78.50 canted frame. The (369D/E/FF 500N)
reels permit the pilot and copilot freedom for
slow, deliberate shoulder movement, but lock (Ref. Figure 201, Figure 202 and Figure 203)
with any sudden forward movement. Full (1). For access to seat belt attach fittings,
extension or retraction of the straps on the remove crew compartment seats.
springloaded reels is approximately 25 inches
(63.5 cm). (2). Remove inertia reel, with harness, from
canted bulkhead lateral beam by
Some installations have a handle: with the removing four bolts.
handle up, the inertia reel operates normally;
with the handle down, the inertia reel is locked (3). Install replacement harness by securing
up to restrain movement. inertia reel, with harness, to canted
bulkhead lateral beam.
2. Seat Belts/Inertia Reel Description and
Operation (600N) (4). Install replacement seat belts and
shoulder straps as shown. Place snap
The crew seats utilize a fourpoint restraint end fittings up or down to eliminate any
harness. This harness combines the lap seat twist in seat belt.
belts with double shoulder straps attached to
an inertia reel mechanism. Both mid and aft (5). Tongue portion of center passenger lap
passenger seats are equipped with a three belt must be installed on right side and
point restraint system. The lap seat belt and buckle portion on left side as shown.
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MAINTENANCE MANUAL
INERTIA REEL FITTING

SNAP END
FITTING
SEAT BACK
SEAT BELT FITTING

NOTE 1 ATTACHMENT
INERTIA REEL
FLOOR STRUCTURE
INERTIA REEL
HARNESS MUST UNREEL
IN DIRECTION SHOWN
NOTE 2
41 3
90 LIMITS OF CUTOUT
IN ALUM. HOUSING
INERTIA REEL
NOTE 1
NOTES:
1. SHOWN WITHOUT CUSHION
FOR CLARITY.
2. CENTER CUSHIONS AND SEAT
BELTS ONLY FOR 3PLACE
SEATING.
CREW COMPARTMENT INERTIA REEL
G252002
Figure 201. Seat Belt/Inertia Reel Installation (Sam Browne Style) (369D)
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MAINTENANCE MANUAL
SNAP END FITTING

(HOOK UP)
SEAT BELTS AND SHOULDER HARNESSES PASSENGER / CARGO

COMPARTMENT AFT
BULKHEAD
SNAP END FITTING

(HOOK DOWN)
SNAP END FITTING
(HOOK UP) NYLON WEBBING
SHOULDER STRAP
ADAPTER
NOTE: SLIDE BAR HARNESS SNAP END FITTING (NOTE)
LENGTH ADJUSTER. (HOOK UP)
SNAP END FITTING
(HOOK DOWN)
NYLON WEBBING
SEAT BELT
INERTIA REEL
BUCKLE
LATCH
ADAPTER
SNAP END FITTING
ADAPTER (HOOK DOWN)
ADAPTER (NOTE)
(NOTE)
NYLON WEBBING
SHOULDER STRAP
SNAP END HARNESS MUST UNREEL
FITTING IN DIRECTION SHOWN
41 3
90 LIMITS OF CUTOUT
BUCKLE IN ALUM. HOUSING
ADAPTER
LATCH
ADAPTER FITTING
(NOTE)
SNAP END FITTING INERTIA REEL
NYLON WEBBING
SEAT BELT
PILOT AND COPILOT SEAT BELT AND SHOULDER HARNESS ASSEMBLY G252003
Figure 202. Seat Belt/Inertia Reel Installation (Yoke Style) (369D)
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INERTIA REEL (2)
SEAT BACK CUSHION
VELCRO STRIP
FASTENER (TYP)
SUPPORT CUSHION
SEAT BOTTOM CUSHION AFT SUPPORT FIT-

TING AND HEIGHT
ADJUSTMENT
INERTIA REEL (2)

SEAT BACK LOCK PIN
CUSHION
LOWER FRAME
RELEASE PIN SUP- FLOOR STRUCTURE
PORT LEG AND
HEIGHT ADJUSTMENT
SEAT BOTTOM
CUSHION
INERTIA REEL (2)
CREW COMPARTMENT
VELCRO STRIP
SEAT STRUCTURE
FASTENER (TYP)
G252004
Figure 203. Seat Belt/Inertia Reel Installation (Yoke Style) (369E/FF 500N)
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MAINTENANCE MANUAL
5. Crew Seat Belt/Harness Replacement With (2). Remove inertia reel, with harness, from
Manual Lock Option (369D/E/FF 500N) fiberglass mount by loosening four bolts
and upper ferrule nut.
(Ref. Figure 204 and Figure 205) (3). Install seatbelts by fastening snap type
end fittings to bulkhead structure
fittings.
(1). Remove seatbelts by unfastening snap (4). Install inertia reel, with harness, to
type end fittings from bulkhead fiberglass mount with ferrule nut and
structure fittings. four bolts, nuts and washers.
CONTROL HEAD ROTATED

90 CW FOR CLARITY
UPPER FERRULE NUT

INERTIA AUTOMATIC
REEL ASSY MANUAL LOCK
LOWER
FERULE
NUT
CABLE
CONTROL ASSY
ADJUSTER TAB RELEASE
(TYP) (TYP)
01019351 SHOULDER
HARNESS ASSY
1.882.12 IN. (4.7765.385 CM)

WIDE WEBBING
2.883.12 IN. (7.3157.925 CM)

ADJUSTER WIDE WEBBING LAP BELT ASSY
END FITTING LINK LATCH (01019361 ASSY)
ADJUSTER
G252006A
Figure 204. Webbed Shoulder Harness and Seat Belt Installation with Manual
Inertia Reel Lock (369D)
Page 205
252000 Revision 23
MAINTENANCE MANUAL
LOW SHOULDER BEAM INSTALLATION HIGH SHOULDER BEAM INSTALLATION G252005
Figure 205. Crew Inertia Reel Installation with Manual Inertia Reel Lock
(369D/E/FF 500N)
6. Seat Belt/Inertia Reel Testing leased, harness strap should automati-
cally reel back into reel. Exert a sudden
(Ref. Pull tests of seat belts and shoulder strap forward pull on seat belt or shoulder
harnesses shall be accomplished in accordance strap to ensure inertia reel locks.
with FAA AC 43.131A, Aircraft Inspection
and Repair, and TSO C22. (2). Inspect inertia reels, snap end fittings,
adjusters, links, buckles, latches and
7. Seat Belt/Inertia Reel Inspection belt attachment fittings for cracks,
wear, corrosion and deformation. Check
Ensure center passenger lap for freedom from binding, ease of
WARNING belt is installed with tongue
adjustment and operation as applicable.
portion to the right of the seat and If doubt exists as to strength, perform
buckle portion to the left. (Quick re- pull test (Ref. Seat Belts/Inertia Reel
lease of the lap belt and shoulder strap Testing).
may be impaired if the assembly is im-
properly installed.) If tongue and (3). Inspect shoulder harnesses and seat
buckle portions are reversed, remove belts for worn, frayed or deteriorated
and reinstall in correct positions and condition, and loose stitching.
document reinstallation in Compliance
Record of Helicopter Log Book. (4). (Manual Lock Option) Check mechani-
cal inertia lock mechanism for proper
(1). Pull seat belt or shoulder strap out of operation, with handle up and with
inertia reel to full extended length. handle down. Inspect fiberglass mounts
Ensure harness strap cannot be pulled for cracking and separation. Inspect
out of inertia reel. With tension re- laminates for debonding.
Page 206
Revision 23 252000
MAINTENANCE MANUAL
8. Seat Belt/Inertia Reel Repair (2). Remove hardware that attaches inertia
reel to mounting surface.
(1). Replace seat belts and shoulder straps
if fabric is frayed, worn, deteriorated,
stitching is loose, or if enertia reels are (3). Remove complete seat belt restraint
destroyed or do not function properly. harness from seat.
(2). Polish minor nicks and scratches. B. Seat Belt/Restraint Harness Installation
Restore protective finish to aluminum
parts as required.
(1). Position lap seat belt and shoulder
(3). Repair fiberglass mounts (Ref. Sec. harness into seat assembly.
253000, Boltaron Trim Panels
Repair). (2). Engage end fittings attaching lap seat
belts.
9. Seat Belt/Restraint Harness, Crew Seat,
Replacement (600N)
(3). Install hardware attaching inertia reel
(Ref. Figure 206) to mounting surface.
A. Seat Belt/Restraint Harness Removal
(4). Ensure proper engagement and release
(1). Release end fittings to remove lap seat of seat buckle and inertia reel mecha-
belts. nism.
ADJUSTOR
ADJUSTOR
SHOULDER
HARNESS
SHOULDER
HARNESS
LAP ADJUSTOR ADJUSTOR LAP

END FITTING SEAT BELT END FITTING
SEAT BELT
BUCKLE
6G25070
Figure 206. Seat Belt/Restraint Harness Installation, Crew Seat (600N)
Page 207
252000 Revision 23
MAINTENANCE MANUAL
10. Seat Belt/Restraint Harness, Mid 11. Seat Belt/Restraint Harness, Aft
Passenger Seat, Replacement (600N) Passenger Seat, Replacement (600N)
(Ref. Figure 207) These three individual seat (Ref. Figure 207)
belt harnesses are completely contained in the
seat assembly and attach to the seat frame. A. Seat Belt/Restraint Harness Removal
This feature aids in the quick removal and
installation of the mid bench seat assembly. (1). Remove hardware that attaches inertia
reel end of harness to mounting
A. Seat Belt/Restraint Harness Removal surface.
(1). Remove hardware that attaches inertia
reel end of harness to seat back. (2). Release end fitting that attaches lap
belt to mounting surface.
(2). Release end fitting that attaches lap
seat belt to seat frame. (3). Release end fitting that attaches buckle
end of harness to mounting surface.
(3). Release end fitting that attaches buckle
end of harness to seat frame. (4). Remove seat belt/restraint harness.
(4). Remove seat belt/restraint harness. B. Seat Belt/Restraint Harness Installation
B. Seat Belt/Restraint Harness Installation
(1). Position seat belt/restraint harness into
(1). Position seat belt/restraint harness into seat assembly.
seat assembly.
(2). Engage end fitting attaching buckle end
(2). Engage end fitting attaching buckle end of harness to mounting surface.
of harness to seat frame.
(3). Engage end fitting attaching lap belt to
(3). Engage end fitting attaching lap belt to
mounting surface.
seat frame.
(4). Install hardware attaching inertia reel (4). Install hardware attaching inertia reel
end of harness to seat back. end of harness to mounting surface.
(5). Ensure proper engagement and release (5). Ensure proper engagement and release
of seat buckle and inertia reel mecha- of seat buckle and inertia reel mecha-
nism. nism.
Page 208
Revision 23 252000
MAINTENANCE MANUAL
MID SEAT AFT SEAT
END FITTING
INERTIA REEL
MOUNT
INERTIA REEL
ADJUSTOR
END FITTING
BUCKLE
6G25086
Figure 207. Seat Belt/Restraint Harness Installation, Passenger

Seats (600N)
Page 209
252000 Revision 23
MAINTENANCE MANUAL
12. Comfort Clip Installation and Decal position as close as possible next to
Application (369D/E/FF 500N) inertia reel.
(Ref. Figure 208 and Figure 209) The comfort (4). After each flight, reposition comfort clip
clip is designed to maintain proper strap on harness strap at original position
tension and relieve excessive pressure of the next to buckle.
inertia reel shoulder harness on the pilot or
passenger during flight. It is available for (5). Clean panel or door frame where decal
installation on helicopters equipped with Sam is to be applied. Decals will not adhere
Browne style seat belt assemblies. to a greasy or soapy film.
(1). Pry open slot on underside of clip.
(6). Mark location(s) of decal per the
(2). Insert harness strap in slot. illustrations.
(3). After seat belt and shoulder harness (7). Peel backing off decal and position. Use
assembly is fastened and adjusted for a cloth to squeeze all bubbles from
individual comfort and safety, slide under the decal, working from the
comfort clip up on harness strap and center outward.
DECAL
CENTER DECAL BETWEEN END OF

DOOR FRAME AND FIRST SCREW
VIEW LOOKING OUTBOARD FROM

CL OF SHIP TO LH SIDE
COMFORT CLIP INSTALLATION
G252001
Figure 208. Comfort Clip Installation and Crew Compartment Decal

Application (369D/E/FF 500N)
Page 210
Revision 23 252000
MAINTENANCE MANUAL
TO APPLY DECAL:
1. CLEAN PANEL AREA WHERE DECAL IS TO BE APPLIED.
DECAL WILL NOT ADHERE TO A GREASY OR SOAPY FILM.
2. MARK LOCATION OF DECAL PER THE ILLUSTRATION.
3. PEEL BACKING OFF DECAL AND POSITION. USE A CLOTH
TO SQUEEZE ALL BUBBLES FROM UNDER THE DECAL,
WORKING FROM THE CENTER OUTWARD.
CL SHIP
DECAL
5.00 0.25 IN.

PANEL ASSEMBLY (12.70 0.635 CM)
G252000A
Figure 209. Comfort Clip Decal Application Passenger Compartment

(369D/E/FF 500N)

252000 Revision 23
MAINTENANCE MANUAL
Section
252100
Seating/Belts (Four
on the Floor)
MAINTENANCE MANUAL
SEATING/BELTS (FOUR ON THE FLOOR)

1. General (3). Remove seat belt assemblies and
shoulder straps by unsnapping hooks at
NOTE: This option has an aircraft effectivity structuremounted fittings.
limit. Refer to CSPIPC4 for effectivity.
B. Seating/Belt Installation
The four on the floor seating and belt installa-
tion is designed for maximum use of the (Ref. Figure 902 and Figure 903)
passenger compartment for transportation of
personnel. The installation consists of four (1). Install seat assemblies by placing seat
floorinstalled seat assemblies with seat belts in position and inserting tabbed rivets
and shoulder straps at each position. The two into holes in floor stiffeners (Ref.
aftfacing seat positions include head and Figure 903).
back restraint panels mounted on Cant. Sta. (2). Install restraint panels by securing
78.50 structure. each panel at bracket assemblies with
The shoulder strap is adjusted to cross the four screws and washers (Ref.
passengers chest from outboard shoulder to Figure 902).
center of lap where it joins the seat belt (3). Install seat belt assemblies and
assembly. Seat belts are adjusted by individual shoulder straps by snapping hooks to
passengers for a close and comfortable fit. structuremounted fittings.
The installation for the early configuration is 3. Seating/Belt Inspection
designed for use with a high shoulder beam.
The current configuration installation is used (Ref. Sec. 252000, Seat Belt/Inertia Reel
for a low shoulder beam. Inspection)
NOTE: Shoulder straps for aftfacing passen- 4. Seating/Belt Cleaning
gers are installed on early configuration he-
licopters only. (Ref. Sec. 202000, Fuselage Interior Trim or
Upholstery Cleaning or 252000, Crew Seat
2. Seating/Belt Replacement Belt/Harness Cleaning)
A. Seating/Belt Removal 5. Seating/Belt Repair
(Ref. Figure 902 and Figure 903) (1). Repair minor tears and cuts to the seat
and restraint panel coverings (Ref. Sec.
(1). Remove seat assemblies by lifting 252000, Seat Belt/Inertia Reel
tabbed rivets from holes in floor Repair).
stiffeners (two per seat), then lift seat
up (Ref. Figure 903). (2). Replace unserviceable seats and
restraint panels.
(2). Remove restraint panels by removing
four screws and washers from each (3). Seat belts or shoulder straps that show
panel bracket assembly (Ref. signs of wear, deterioration, fraying, or
Figure 902). loose stitching must be replaced.

252100 Revision 23
MAINTENANCE MANUAL
SEATING/BELTS (FOUR ON THE FLOOR)

1. Seating/Belts (Four on the Floor) Initial (3). Remove passenger compartment carpet
Installation floor covering.
NOTE: This option has an aircraft effectivity (4). Remove aft trim panel from Cant. Sta.
limit. Refer to CSPIPC4 for effectivity. 78.50 and disconnect cigarette lighter
wiring.
Consult the optional equipment table (Ref.
Table 202, Sec. 010000) for model applicabil- (5). Remove bulkhead trim panels or
ity for seating/belts (369H90035) installations. insulation blankets at Sta. 124.00 in
The 501 and 503 installations are covered in area of WL 40.00 and BL 20.00 right
the following paragraphs. and left seats.
A. Preparation for Installation (6). (369D only) Remove crew compartment
outboard seat backs.
(Ref. Section 910000) C. Seating and Belts Installation General
Item Nomenclature Installation of the seating and belts for four
CM318 Primer includes procedures for installing restraint
panels on Cant. Sta. 78.50, seat assemblies,
shoulder straps, and seat belt assemblies.
(1). Ensure all electrical switches are set to
OFF position. Recheck master switch
for OFF position. Consumable Materials
(2). Identify all components and attaching Item Nomenclature
hardware to be removed for access to
CM318 Primer
work areas. Protect components from
damage and foreign matter until
reinstalled. NOTE:
(3). After drilling or cutting, remove burrs D Use Cleco clamps and fasteners as re-
and metal particles. Apply a thin coat of quired to facilitate rivet installation, and
primer (CM318) to all bare metal areas. install rivets with wet primer (CM318).
NOTE: An application of colormatched paint D Rivets are equally spaced and are normal-
may be applied to primer painted reworked ly positioned twice the diameter of the riv-
areas and to installed hardware. et shank from the outside edge of the ma-
terial, edge joggle, or flange radius.
B. Removal of Existing Equipment
D. Cant. Sta. 78.50 Brackets, Fittings and
Prior to installing the seating and belts for Restraint Panels Installation
four, a limited number of items must be
removed from the helicopter passenger (Ref. Figure 901, Figure 902 and Figure 904)
compartment to accommodate installation.
(1). On Cant. Sta. 78.50, WL 22.45, remove
(1). Remove passenger compartment seats four existing bracket rivets in area of
by releasing quickdisconnects on LBL 8.25 and four rivets in area of LBL
seating structure at floor and firewall 19.25.
fittings.
(2). Position bracket assemblies to match
(2). Remove existing passenger compart- holes in removed rivet pattern. Locate
ment seat belt and shoulder strap and drill four 0.1285 inch (3.2639 mm)
assemblies. holes in each bracket.
Page 901
252100 Revision 23
MAINTENANCE MANUAL
LBL 15.50 LBL 8.50 BRACKET

BRACKET ASSEMBLY
ASSEMBLY
0.50 IN. (12.7 MM) (TYP)
RIVET (2) RIVET (2)

CANT. STA 78.50
0.75 IN. (19.05 MM)
0.83 IN. (21.082 MM)
LH SHOWN 0.50 IN. (12.7 MM) 0.42 IN. (10.668 MM)

RH OPPOSITE
RIVET (4) RIVET (4)

CANT. STA 78.50
BRACKET ASSEMBLY
BRACKET ASSEMBLY
NOTES: DRILL 0.2170.229 IN.

(5.51185.8166 MM) HOLES (4) IN EACH
RESTRAINT PANEL ASSEMBLY; LOCATE PICK UP EXISTING RIVETS
FROM BRACKETS. DRILL HOLES IN TRIM
PANEL ASSEMBLIES AS APPLICABLE. LBL LBL LBL LBL LBL LBL
20.75 19.25 17.00 LH SHOWN 11.30 8.25 6.00
RH OPPOSITE
LBL LBL BL RBL

15.50 8.50 0.00 8.50 RESTRAINT PANEL
RESTRAINT PANEL LH LH RH ASSEMBLY
ASSEMBLY D
BRACKET ASSEMBLY
RESTRAINT PANEL
BRACKET ASSEMBLY
ASSEMBLY
WL 45.36
BRACKET WL 45.30
ASSEMBLY BRACKET ASSEMBLY
FITTING
SUPPORT FITTING SUPPORT
TRIM
SHOULDER STRAP PANEL
SHOULDER
STRAP
WL 28.44
BRACKET
ASSEMBLY WL 22.45
WL 21.50 SEAT AS-
BRACKET ASSEMBLY SEMBLY
LBL 20.75 LH D BRACKET AS- RBL 20.75 RH
LBL 19.25 LH SEMBLY RBL 19.25 RH
LBL 17.00 LH RBL 17.00 RH
RESTRAINT PANELS BRACKET CANT. STA 78.50 WL 13.10
LOCATION HIGH BULKHEAD
SECTION DD
G252008A
Figure 901. Restraint Panel Assemblies and Hardware Installation (369D)
Page 902
Revision 23 252100
MAINTENANCE MANUAL
BRACKET ASSEMBLY LBL 19.50 LBL 8.50 BRACKET

ASSEMBLY
0.50 IN. (12.7 MM) (TYP)
RIVET (2) RIVET (2)

CANT. STA 78.50
0.94 IN. (23.876 MM)
0.42 IN. (10.668 MM)
1.02 IN. (2.59 CM)
0.50 IN. (12.7 MM)

LH SHOWN
RH OPPOSITE
RIVET (4) RIVET (4)

CANT. STA 78.50
BRACKET ASSEMBLY BRACKET ASSEMBLY
NOTES: DRILL 0.2170.229 IN.

(5.51185.8166 MM) HOLES (4) IN EACH
RESTRAINT PANEL ASSEMBLY; LOCATE PICK UP EXISTING RIVETS
FROM BRACKETS. DRILL HOLES IN TRIM
PANEL ASSEMBLIES AS APPLICABLE. LBL LBL LBL LBL LBL LBL
20.75 19.25 17.00 LH SHOWN 11.30 8.25 6.00
RH OPPOSITE
RBL
LBL LBL BL RBL 19.50
19.50 8.50 0.00 8.50 RH
LH LH RH
D RESTRAINT PANEL
RESTRAINT PANEL
ASSEMBLY
ASSEMBLY
RESTRAINT PANEL
BRACKET ASSEMBLY
ASSEMBLY
BRACKET
ASSEMBLY
BRACKET ASSEMBLY
WL 37.85
TRIM
PANEL
WL 28.44
BRACKET
ASSEMBLY WL 22.45
WL 21.50 SEAT
BRACKET ASSEMBLY ASSEMBLY
LBL 20.75 LH D BRACKET AS- RBL 20.75 RH
LBL 19.25 LH SEMBLY RBL 19.25 RH
LBL 17.00 LH
RBL 17.00 RH
LBL 11.30 LH
RBL 11.30 RH
LBL 8.25 LH
RBL 8.25 RH
RESTRAINT PANELS BRACKET CANT. STA 78.50
LOCATION HIGH BULKHEAD WL 13.10
SECTION DD
G252007A
Figure 902. Restraint Panel Assemblies and Hardware Installation (369E/FF 500N)
Page 903
252100 Revision 23
MAINTENANCE MANUAL
(3). Hold brackets in position with Cleco (8). (369D only) Install shoulder strap
fasteners and drill four 0.1285 inch fittings for aftfacing passenger seat as
(3.2639 mm) holes through upper flange follow:
of each bracket and through Cant. Sta.
78.50 web. (a). On left side of Cant. Sta. 78.50
bulkhead frame, locate four existing
(4). Install bracket assemblies with 16 nutplates in area of WL 41.06 and BL
rivets. 24.74.
(5). Repeat last four steps to install two (b). Attach shoulder strap fitting with
bracket assemblies to opposite side. four screws.
(6). (369D only) Install bracket assemblies (c). On right side of Cant. Sta. 78.50
as follows: bulkhead frame, locate four existing
nutplates in area of WL 41.06 and BL
(a). On WL 45.33, position bracket 24.74.
assembly at LBL 15.50 and drill two
0.1285 inch diameter holes through (d). Attach shoulder strap fitting with
bracket and Cant. Sta. 78.50 channel. four screws.
(b). Install bracket assembly with two (e). Attach L/H fitting to nutplates in L/H
blind rivets. tee using four screws.
(c). On WL 45.33 L/H, position bracket (f). Attach R/H fitting to nutplates in
assembly at LBL 8.50 and drill two R/H tee using four screws.
0.1285 inch diameter holes through (g). Cut out slots in removed passenger
bracket and Cant. Sta. 78.50 channel. compartment forward trim panels to
accommodate lugs of shoulder strap
(d). Install bracket assembly with two
fittings.
blind rivets.
(9). Drill four 0.2170.229 inch
(e). Repeat last four steps to install two (5.51185.8166 mm) holes in forward
bracket assemblies R/H opposite. trim panel, and four holes in each
(7). (369E/FF only) Install bracket assem- restraint panel. Locate holes from
blies as follows: bracket assemblies and install as in
steps (1). thru (8).
(a). On WL 37.85, position bracket
(10). Reinstall forward trim panel (connect
assembly at LBL 19.50 L/H. Drill two
cigarette lighter wiring).
0.1285 inch (3.2639 mm) holes
through bracket and Sta. 78.50 (11). Install passenger compartment carpet
channel. floor covering.
(b). Install bracket assembly with two (12). (369D only) Install fitting cap to L/H
blind rivets. and R/H shoulder strap fittings with
two screws each side.
(c). On WL 37.85, position bracket
assembly at LBL 8.50 L/H. Drill two (13). Install restraint panel to L/H side over
0.1285 inch (3.2639 mm) holes trim panel with four washers and
through bracket and Cant. Sta. 78.50 screws.
channel.
(14). Install restraint panel to R/H side over
(d). Install bracket assembly with two trim panel with four washers and
blind rivets. screws.
(e). Repeat last four steps to install R/H (15). Reinstall crew compartment seat back
bracket assemblies. assemblies.
Page 904
Revision 23 252100
MAINTENANCE MANUAL
E. Seat Assemblies Installation NOTE: All seat belt assemblies are to be in-
stalled as shown and as noted on cloth iden-
(Ref. Figure 903) tification labels attached to each seat belt
NOTE: Seat assemblies are positioninter- assembly. The two center belts are installed
changeable. with hooks down.
(1). Position seat assemblies on floor (7). Connect adjustable portion of seat belt
structure to locations specified. assembly to the R/H fitting and nonad-
justable portion to center fitting.
(2). Secure seats in position by pressing
tabbed rivets into holes in floor stiffen- (8). Connect adjustable portion of seat belt
ers. assembly to L/H fitting and nonadjust-
able portion to center fitting.
F. Aft Seat Belt Assemblies and Shoulder
Straps Installation G. Forward Seat Belt Assemblies and
Shoulder Straps Installation
(Ref. Figure 903)
(Ref. Figure 904)
(1). On both left and right sides of Cant.
Sta. 128.00 locate four existing nut- (1). (369D only) Connect a shoulder strap to
plates in areas of WL 40.0 and BL 20.0. each shoulder strap fitting on Cant.
Sta. 78.50.
(2). Attach a shoulder strap support fitting
on each side, using four washers and NOTE: Adjust shoulder strap to cross passen-
screws for each fitting. gers chest from outboard shoulder to inner
center lap area.
(3). Cut out slots in removed trim panels or
insulation blankets to accommodate (2). Locate the four tiedown fitting holes on
lugs of new support fittings. the first floor stiffener aft of Cant. Sta.
78.50.
(4). Reinstall trim panels or insulation
blankets. (3). Install a cargo tiedown fitting in each
floor stiffener hole.
(5). Connect a shoulder strap to each
fitting. (4). Connect adjustable portion of seat belt
assembly to the L/H fitting and the
NOTE: Adjust shoulder strap to cross passen- nonadjustable portion to the L/H center
gers chest from outboard shoulder to inner fitting.
center of lap.
(5). Connect adjustable portion of seat belt
(6). Locate the three existing cargo floor assembly to the R/H fitting and the
seat belt fittings on the passenger nonadjustable portion to the R/H center
compartment floor at Sta. 124.00. fitting.
Page 905
252100 Revision 23
MAINTENANCE MANUAL
H. Weight and Balance Data

(Ref. Table 901) After installation, incorporate
changes to helicopter weight and balance
records as instructed (Ref. Sec. 081000).

Weight Arm Moment
Configuration
369H90035501
Added +30.2 (+13.698) +93.5 (+237.49) +2824 (+3253.6)
Removed 32.7 (14.832) +108.6 (+275.84) 3551 (4091.2)
369H90035503
Added +31.2 (+14.152) +92.1 (+233.93) +2874 (+3311.2)
Removed
Seat Belts (2) 5.1 (2.313) +117.2 (+297.69) 598 (689.0)
Bench Seat 24.7 (11.204) +111.0 (+281.94) 2742 (3159.1)
Page 906
Revision 23 252100
MAINTENANCE MANUAL
NUT
GROMMET
RIVET
CARGO TIEDOWN FITTING
(4 PLCS)
STA. 78.50 BELT ASSEMBLY STA. 124.00 RIVET TAB (TYP 4 PLCS)
BELT ASSEMBLY
SEAT ASSEMBLY
(4 PLCS)
EXISTING CARGO FLOOR

SEAT BELT FITTINGS
(3 PLCS)
4.0 IN.
(10.16 CM) 4.0 IN.
(10.16 CM)
4.0 IN. 1.25 IN.

(10.16 CM) (3.175 CM)
BELT ASSEMBLY
BELT ASSEMBLY
SEAT LOCATIONS
G252010A
Figure 903. Seat Belt and Seat Assemblies Installation (369D/E/FF 500N)
Page 907
252100 Revision 23
MAINTENANCE MANUAL
SHOULDER STRAP
ATTACH FITTING
L.H. SHOWN
R.H. OPPOSITE
SCREW (4 REQD)
HIGH BULKHEAD WASHER (4 REQD)
STA. 124.00 SHOULDER STRAP FITTING
SHOULDER STRAP
ATTACH FITTING
R.H. SHOWN
L.H. OPPOSITE
FITTING CAP
R.H. SHOWN
L.H. OPPOSITE SCREW (4 REQD)
SCREW (2 REQD)
LOW BULKHEAD
STA. 78.50 SHOULDER STRAP FITTING
SHOULDER STRAP SHOULDER STRAP

(TYP) (TYP)
STA. 78.50 WL 28.44 WL 32.00 STA. 124.00
STA. 78.50 SHOULDER STRAP AND FITTINGS STA. 124.00 SHOULDER STRAP AND FITTINGS
NOTE: PICK UP EXISTING NUTPLATES LO-

CATED ON CANT. STA. 78.50 BULKHEAD FRAME
AND CANT. STA. 124 BULKHEAD FRAME. G252009
Figure 904. Shoulder Straps and Fittings Installation (369D/E/FF 500N)
Page 908
Revision 23 252100
MAINTENANCE MANUAL
Section
253000
Interior Trim
MAINTENANCE MANUAL
INTERIOR TRIM
1. Interior Trim A. Cyclic Stick Control Cover Replacement
(L/H Command)
Trim panels, covers, and applicable attaching
devices are found in the following locations:
(Ref. Figure 201)
(1). Models 369D/E/FF 500N crew
compartment (Ref. Figure 201). (1). Remove four upper attaching cover
screws. Remove velcro attached boot
(2). Models 369D/E/FF 500N passenger assemblies from cover. Tip cover
compartment (Ref. Figure 202). forward to remove two lower attaching
(3). Model 369D crew and passenger screws.
compartments R/H command helicop-
ters with center console (Ref. (2). Remove cover from cyclic stick assem-
Figure 203). bly and slip boot assemblies over cyclic
stick grips.
(4). Floor trim covering and applicable
methods of attachment (Ref.
Figure 204). (3). To replace, slip boot assemblies over
cyclic stick grips and position cover in
A. Cyclic Stick Control Cover place. Attach boot assemblies to cover
with the velcro fasteners.
(Ref. Figure 201) A cyclic stick control cover
protects the cyclic control linkage from objects (4). Tip cover forward and install two lower
that might jam or foul control linkage. The attaching screws. Install four upper
cover extends between the pilots and copilots attaching screws.
cyclic sticks at the seat bulkhead and covers
the cyclic control linkage. Cyclic stick openings
in the cover are protected by boot assemblies B. Copilots Collective Pitch Stick Cover
(dust covers) secured to the cover with Velcro Replacement (L/H Command)
hook and pile fasteners. The cyclic sticks pass
through elastic ringed openings in the dust (Ref. Figure 201)
covers.
(1). Remove crew seats.
B. Copilots Inboard Collective Pitch Stick
Cover
(2). Remove attaching hardware. While
The inboard collective pitch stick cover on L/H carefully removing cover, ensure sliding
command helicopters provides access to the protective cover remains fixed to
underseat flight controls linkage and forms a collective pitch stick. Partial removal of
protective guard for the collective friction the cyclic stick control cover may be
mechanism on the inboard collective pitch required.
stick. A sliding protective cover at the collec-
tive pitch stick slotted opening guards against (3). Spread sliding cover at collective stick
foreign object entry. and remove. If necessary, remove nylon
grommet on stick (Ref. Sec. 671000,
2. Interior Trim Replacement Pilots Collective Pitch Stick Replace-
NOTE: Electrical wires from passenger com- ment).
partment cigarette lighter, optional utility
light, and running time meter must be dis- (4). To replace, install nylon grommet on
connected before removing and reconnected collective stick. Spread sliding cover at
before installing associated trim panel or collective stick hole and fit over nylon
cover (Ref. Chap. 96). grommet.
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MAINTENANCE MANUAL
VELCRO FASTENER
CONTROL TUNNEL PANEL

(NOTES 1, 5)
CAP
(NOTE 2)
VELCRO
FASTENER
4 PLCS
MAP CASE SHOULDER BEAM PANEL

TRIM COVER
(NOTE 4)
6 PLCS
MAP POCKET LH BOOT

RH BOOT ASSEMBLY
ASSEMBLY
CYCLIC STICK CONTROL COVER
3 PLCS LID
VELCRO
FASTENER
MAP CASE COVER
COLLECTIVE STICK COVER
NOTES:
1. USED ONLY WITH OPTIONAL DUAL CONTROLS.
2. USED ONLY WITH SINGLE CONTROLS.
3. REMOVED FOR OPTIONAL UTILITY LIGHTS.
4. TRIM COVER SHORTER ON HIGH BULKHEAD MODELS. COPILOTS COLLECTIVE PITCH STICK COVER
(NOTE 1)
5. TRIM COVER LONGER ON HIGH BULKHEAD MODELS. G2530011
Figure 201. Crew Compartment Interior Trim (Sheet 1 of 2)
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Revision 23 253000
MAINTENANCE MANUAL
VELCRO FASTENER
ASSIST STRAP
CANTED BULKHEAD PANEL
(RIGHT SIDE)
3 PLCS
2 PLCS
2 PLCS
DOOR PANEL UPPER SIDE PANEL
ASSIST HANDLE
NOTE 6
VELCRO FASTENER
LOWER INSTRUMENT 4 PLCS

HOUSING PANEL
8 PLCS
FORWARD PANEL NOTES: (CONT.)

6. USED FOR RUNNING TIME METER ON MODEL 369D ONLY.
7. UNLESS OTHERWISE INDICATED, LEFT SIDE ITEMS ARE
OUTBOARD AFT PANEL
SHOWN (EQUIVALENT RIGHT SIDE ITEM IS APPROXIMATELY
MIRROR IMAGE OPPOSITE).
8. DOOR MAIN TRIM PANELS NOT SHOWN. G2530012
Figure 201. Crew Compartment Interior Trim (Sheet 2 of 2)
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253000 Revision 23
MAINTENANCE MANUAL
VELCRO FASTENER COVER

(8 PLCS) (2 PLCS)
VELCRO FASTENER
SCREW
(4 PLCS)
SCREW
(2 PLCS)
STANDOFF
BRACKET (2 PLCS)
HIGH FORWARD BULKHEAD PANEL
(LOOKING FORWARD)
VELCRO FASTENER STANDOFF

(2 PLCS)
SCREW
(2 PLCS)
BRACKET
LOW FORWARD BULKHEAD PANEL

(LOOKING FORWARD)
BRACKET LIGHTER
BLANK COVER
SCREW
(6 PLCS) ASHTRAY
LOW BULKHEAD CONVENIENCE PANEL
NUT
(12 PLCS)
WASHER
(12 PLCS)
SCREW
(4 PLCS) SCREW
AFT DOOR FRAME PLUG (12 PLCS)
(LEFT SIDE)
HIGH BULKHEAD CONVENIENCE PANEL COVER

(NOTES 1, 2) BULKHEAD PANEL
NOTES: POCKET
1. NOT USED WITH OPTIONAL ROTOR BRAKE EQUIPMENT.
2. FOR INFORMATION ON OPTIONAL EQUIPMENT USED ON LITERATURE POCKET
THIS PANEL, REFER TO OPTIONAL EQUIPMENT LIST
(REF. SEC. 010000). G2530021
Figure 202. Passenger Compartment Interior Trim (Sheet 1 of 2)
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Revision 23 253000
MAINTENANCE MANUAL
SCREW
(16 PLCS)
SCREW
(5 PLCS)
EARLY CONFIGURATION CURRENT CONFIGURATION
UPPER AFT BULKHEAD PANEL

(LEFT SIDE)
OIL LEVEL
CHECK COVER
PLUG BOTTOM
(BOTH SIDES)
5 PLCS
LOWER AFT BULKHEAD PANEL
VELCRO FASTENER
MAIN TRANSMISSION
ACCESS PANEL
VELCRO FASTENER
8 PLCS
TRANSMISSION PANEL
DOOR STRUCTURE
5 PLCS
STRUCTURE
DOOR PANEL
(LEFT SIDE)
ISOLATOR NUT MOUNT INSTALLATION

(TYP)
G2530022
Figure 202. Passenger Compartment Interior Trim (Sheet 2 of 2)
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253000 Revision 23
MAINTENANCE MANUAL
(5). Position cover over collective stick and F. Carpeting

start upper end of sliding cover into
cover tracks. Consumable Materials
(6). Slowly lower cover and guide remainder
Item Nomenclature
of sliding cover upward in cover tracks.
CM405 Adhesive
(7). Secure with screws and washers. CM718 Tape, doublefaced
(8). Install crew seats.

NOTE: Carpeting is secured in place with dou-
C. Inboard Collective Pitch Stick Cover blefaced tape or bonded with adhesive, and
Replacement (R/H Command) should not be removed unless replacement
or repair is required.
(Ref. Figure 203) At installation, tuck bottom
(1). Tear away carpeting (if bonded) and
edge of lower curtain under support.
clean surface with wire brush. Bond
Curtains must not fold inward replacement carpeting using adhesive
CAUTION through full travel of the collec- (CM718).
tive stick. Folding inward may result in en- (2). Lift carpeting (if taped) away from floor
tanglement with collective stick friction and remove doublefaced tape. Apply
gear mechanism. new doublefaced tape (CM718) and
press replacement carpeting in position.
D. Transmission Panel
3. Interior Trim Inspection
(Ref. Figure 203) Remove low or high bulkhead
convenience panel before removing transmis- (1). Inspect interior trim for tears, cuts,
sion panel. breaks, or other evidence of unservice-
able condition.
E. Log Book Holder (Optional for R/H
(2). Inspect trim panels and covers for
Command)
loose, damaged, or missing Velcro
(Ref. Figure 203) fasteners, as applicable.
(3). Inspect fuselage structure for loose,
Consumable Materials damaged, or missing Velcro fasteners,
(Ref. Section 910000) rivnuts or isolator nut mounts, as
Item Nomenclature applicable.
CM217 Isopropyl alcohol (4). Inspect carpeting for cuts, tears, or
CM432 Dichloromethane other unserviceable condition.
CM433 Ethylene chloride (5). Inspect foot fairings, floor trim, and
access doors for cuts, breaks or cracks.
(1). Remove upper two screws and loosen (6). Inspect Velcro fasteners on access flap
the bottom screws. for security of attachment or other
damage.
(2). Lift holder up and out.
(7). (L/H command helicopters) Inspect
(3). Repair cracks or separation by cleaning sliding cover of copilots collective pitch
with isopropyl alcohol (CM217); then stick cover for freedom of movement in
apply ethylene dichloride (CM433) or cover tracks. Inspect stowage lid for
dichloromethane (CM432) to patch or condition and positive fastening.
mate surfaces. A. Interior Trim Cleaning
(4). Join immediately with light pressure to (Ref. Sec. 202000, Fuselage Interior Trim
cement joint. and Upholstery Cleaning)
Page 206
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MAINTENANCE MANUAL
TRANSMISSION PANEL
INSTALLATION
OIL LEVEL
CHECK COVER
PLUG BUTTON
(BOTH SIDES) MAIN TRANSMISSION
ACCESS PANEL
CHIP DETECTOR
COVER PLUG
TRANSMISSION
PANEL
AFT BULKHEAD INSTALLATION

UPPER BULKHEAD PANEL
(RIGHT HAND)
UPPER BULKHEAD PANEL CHECKLIST

(LEFT HAND)
LOWER BULKHEAD PANEL MAGNETIC

COMPASS
CARD
SEAT FITTING COVER
LOGBOOK HOLDER
CONVENIENCE PANEL
INSTALLATION LOGBOOK HOLDER
INSTALLATION
PLUGS
CONVENIENCE PANEL
ISOLATOR NUT MOUNT
INSTALLATION
BLANK COVER
CONVENIENCE
TRIM PANEL NUT
PANEL COVER
MOUNT
G2530031
Figure 203. Crew and Passenger Compartment Interior Trim R/H Command (Sheet 1 of 2)
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MAINTENANCE MANUAL
CIRCUIT BREAKER
PANEL
ASH RECEIVER AND

CIGARETTE LIGHTER
PANEL
STICK COVER
SUPPORT TUBE
CLAMP
PILOT COLLECTIVE PITCH SUPPORT TUBE
STICK COVER ASSEMBLY ASSEMBLY
FLEXIBLE CLOSURE
ASSEMBLY
LOWER CURTAIN
PILOTS INBOARD COLLECTIVE
PITCH STICK COVER
UPPER CURTAIN CURTAIN STOP
COTTER PIN
SLIDER
FASTENER STUD
FASTENER BUTTON
EXPLODED VIEW
(ROTATED)
PILOTS CYCLIC
STICK GUARD
CYCLIC CONTROLS
CENTER GUARD
COPILOTS CYCLIC
STICK GUARD
CYCLIC STICK GUARDS
(ROTATED)
G2530032
Figure 203. Crew and Passenger Compartments Interior Trim R/H Command (Sheet 2 of 2)
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MAINTENANCE MANUAL
4. Interior Trim and Carpeting General (1). Remove damaged panel.

Repair
(2). Stopdrill end(s) of crack.
Item Nomenclature (3). Deburr stop drill(s) and clean any
jagged area of crack.
CM405 Adhesive
CM718 Tape, doublefaced
(4). Cut patch from fiberglass cloth to
overlap damaged area or crack, mini-
mum 1 inch (2.54 cm) in all directions.
(1). Remove and replace broken or missing
rivnuts or isolator nut mounts, as (5). Cut second patch to overlap first,
applicable. minimum 1/2 inch (12.7 mm) in all
directions. If required, cut third patch
(2). Bond loose insulation material on to overlap second, minimum 1/2 inch
underside of trim panel or cover using (12.7 mm) in all directions.
adhesive (CM405).
(3). Repair cut or torn floor trim or carpet- (6). Abrade surface of panel in area to be
ing with new application of double patched with emery cloth (CM804).
faced tape (CM718) or adhesive
(CM405), as applicable.
(7). Clean surface by wiping with cloth,
dampened not saturated, with
MEK solvent is flammable.
WARNING Use only in wellventilated 1,1,1trichloroethane (CM222) or
surface cleaner (CM228).
area and away from heat and flame.
NOTE: Loosened Velcro fasteners may be reac- (8). Place panel in horizontal position. Tape
tivated for adhesion by wiping original around area to be repaired with
adhesive with MEK (CM219). masking tape, to catch residual resin.
(4). Replace unserviceable Velcro fasteners

on access flap using adhesive (89). (9). Apply glass cloth (CM501) to panel one
ply at a time.
5. Boltaron Trim Panels Repair
(10). Apply resin (CM505) to material with a
A. Fiberglass Patch Method brush or squeegee.
(Ref. Figure 205)

(11). Continue adding material and resin
until desired thickness has been
Consumable Materials achieved.
Item Nomenclature
NOTE: Heat lamp should be placed a minimum
CM222 1,1,1Trichloroethane
of 12 inches from fiberglass repair area.
CM228 Surface cleaner
CM501 Fiberglass cloth
(12). Allow repair to cure, minimum 45
CM505 Polyester laminating resin minutes, at 265 10F (129 5C). Or
CM804 Emery cloth, fine alternatively, heat lamp may be used
(minimum 2 hours).
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MAINTENANCE MANUAL
NAUGAHYDE
HANDLE (2)
FLOOR CARPETING
STA. 78.50
BULKHEAD
ACCESS DOOR
FOOTWELL PANEL CARPETING DOUBLE
ASSEMBLY FACE TAPE
FLOOR STRUCTURE
FLOOR ACCESS DOOR

ACCESS FLAP RIGHT SIDE TRIM
CARPETING (2) (NOTE)
CARPETING CARPETING
CREW COMPARTMENT
VELCRO
FASTENER
CUTOUT FOR
LEG OF SEAT
STRUCTURE (2)
LEFT SIDE TRIM

CARPETING PASSENGER COMPARTMENT
FLOOR STRUCTURE FLOOR CARPETING
CENTER TRIM
CARPETING
BULKHEAD TRIM (NOTE)
NOTE:
CARPETING IN THIS AREA
IS BONDED IN PLACE.
DOUBLE
FLOOR PAN
FACE TAPE
G253004A
Figure 204. Floor Trim and Covering
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Revision 23 253000
MAINTENANCE MANUAL
B. Solvent Bonding Patch Method (10). After forcing out bubbles, adjust clamps
to minimum pressure required to hold
(Ref. Figure 205) parts together.
(11). If solvent has evaporated at or near

edge of patch, apply more solvent
between mating surfaces using syringe
Item Nomenclature
or eye dropper.
CM435 Tetrahydrofuran (12). Leave clamps in place for a minimum of
20 minutes.
(1). Remove damaged panel. (13). Allow the panel to cure for 24 hours
prior to reinstallation.
(2). Stopdrill end(s) of crack.
C. Epoxy Adhesive Patch Method
(3). Deburr stop drill(s) and clean any
jagged area of crack. (Ref. Figure 205)
(4). Select a piece of boltaron material with
same contour as patch area. Plating Consumable Materials
surfaces must provide a snug fit. Patch (Ref. Section 910000)
material to overlap damaged area a Item Nomenclature
minimum of 1 inch (2.54 cm) in all CM228 Surface cleaner
directions. CM411 Adhesive, epoxy
(5). Clean mating surfaces with aliphatic CM804 Emery cloth, fine
naphtha (CM220). Ensure surfaces are
free from oil, grease or other contami-
nates. (1). Remove damaged panel.
(6). Assemble patch with mating surface of (2). Stopdrill end(s) of crack.
patch in contact with panel but without
(3). Deburr stop drill(s) and clean any
application of pressure.
jagged area of cracks.
Tetrahydrofuran bonding
WARNING solvent is a flammable liq- (4). Select a piece of boltaron material with
same contour as patch area. Mating
uid. Care must be exercised in handl-
surfaces must provide a snug fit. Patch
ing.
to overlap damaged area a minimum of
Solvent shall be applied careful- 1 inch (2.54 cm) in all directions.
CAUTION ly so no excess material will run
over other surfaces and mar the finish. (5). Lightly abrade mating surfaces with
emery cloth (CM804) and clean with
NOTE: On larger parts, solvent shall be applied surface cleaner (CM228).
evenly to mating surfaces with brush.
(6). Air dry for 30 minutes at ambient
(7). Inject tetrahydrofuran (CM435) temperature. Apply adhesive (CM411)
between mating surfaces by means of within 2 hours of drying.
syringe or eye dropper.
(7). Thoroughly mix equal parts of adhesive
(8). Assemble mating surfaces as quickly as by weight. Color should be uniform
possible by firmly pressing together. green. Use unwaxed disposable contain-
er and wooden tongue depressor or
(9). Apply clamps to assembly immediately metal spatula for mixing. Pot life of
after solvent application. Use sufficient mixed adhesive is 45 minutes at
pressure to force out air bubbles. ambient temperature.
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253000 Revision 23
MAINTENANCE MANUAL
FIBERGLASS PATCH METHOD A

0.50 IN. 1.0 IN.
(12.7 MM) (2.54 CM)
STOP DRILL
SOLVENT BONDING AND EPOXY

ADHESIVE PATCH METHOD B & C
1.0 IN.
(2.54 CM)
1.0 IN.
(2.54 CM)
STOP DRILL
BOND AND RIVET PATCH METHOD D
46 X O.D.
PANEL
PATCH
RIVETS
2 X O.D. BOND AND RIVET PATCH METHOD D

STOP DRILL
+0.030 IN.
(0.762 MM) 2 X O.D.
+0.030 IN.
(0.762 MM)
WASHER
(NOTE)
NOTE: USE AN960 WASHER, OF PROPER
SIZE TO FIT RIVET DIAMETER, TO PRECLUDE 46 X O.D.
RIVET TAIL FROM PULLING THROUGH BOLTA-
RON PANEL. G253005A
Figure 205. Boltaron Panel Repair
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Revision 23 253000
MAINTENANCE MANUAL
(8). Spread thin uniform layer (0.0020.010 (3). Lay out rivet pattern on patch and drill
inch) (0.05080.254 mm) of adhesive holes. Position patch on panel and drill
lightly on mating surfaces and clamp holes.
lightly together.
(4). Deburr all holes on both sides of patch
(9). Wipe excess adhesive from bond line. and panel.
(5). Countersink holes on patch if using
(10). The clamps are to remain in place for 8 MS20426A4 rivets.
hours minimum at ambient tempera-
ture or 2 hours at 160 10F (72 (6). Comply with the following procedures if
5C). using Solvent Bonding Patch Method
(tetrahydrofuran).
(11). Allow panel to cure for 24 hours prior to
installation. (a). Clean mating surfaces with naphtha
aliphatic (CM220). Ensure surfaces
are free from oil, grease or other
D. Bond and Rivet Patch Method
contaminates.
(Ref. Figure 205) The following procedure may (b). Set patch in place. Use a minimum
be used in conjunction with one of the above amount of clecos required to hold
bonding procedures (Ref. Solvent Bonding patch in contact with panel without
Patch Method or Epoxy Adhesive Patch applying too much pressure.
Method). If cracks are excessive and/or a piece
of boltaron is not available that fits contour in Tetrahydrofura bonding sol-
repair area, rivets may be used to help secure WARNING vent is a flammable liquid.
patch to panel. Care must be exercised in handling.
Solvent shall be applied careful-
CAUTION ly so no excess material will run
(Ref. Section 910000) over other surfaces and mar the finish.
Item Nomenclature
NOTE: On larger parts, solvent shall be applied
CM220 Naphtha aliphatic evenly to mating surfaces with brush.
(c). Inject tetrahydrofuran (CM435)
CM411 Adhesive, epoxy between mating surfaces by means of
CM435 Tetrahydrofuran syringe or eye dropper.
CM804 Emery cloth, fine
(d). Assemble mating surfaces as quickly
as possible by firmly pressing togeth-
er.
(1). Cut patch to proper size.
(e). Apply clamps to assembly immedi-
(2). Determine rivet spacing. ately after solvent application, with
sufficient pressure to force out air
(a). Rivet spacing to be 46 times rivet bubbles.
diameter.
(f). After forcing out bubbles, adjust
(b). Minimum edge distance to be 2 times clamps to minimum pressure re-
rivet diameter 0.030 inch (0.762 quired to hold parts together.
mm). (g). If solvent has evaporated at or near
edge of patch, apply more solvent
Example :For #4 rivet, minimum between mating surfaces using
edge distance is 0.028 inch (0.7112 syringe or eye dropper.
mm). Rivet diameter 0.125 inch
(3.175 mm) X 2 + 0.030 inch (0.762 (h). Leave clamps in place for a minimum
mm) = 0.280 inch (7.112 mm). of 20 minutes.
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253000 Revision 23
MAINTENANCE MANUAL
NOTE: If gap exists between patch and panel (c). Thoroughly mix equal parts, of
prior to installing rivets, inject tetrahydro- adhesive by weight. Color should be
furan between mating surfaces in immedi- uniform green. Use unwaxed dispos-
ate area of each rivet hole that has a gap usable container and wooden tongue
ing a syringe or eye dropper. depressor or metal spatula for
mixing. Pot life of mixed adhesive is
(i). Rivet patch to panel. 45 minutes at ambient temperature.
(d). Spread a thin uniform layer,
(j). Allow panel to cure for a minimum of
0.0020.010 inch (0.05080.254 mm),
24 hours prior to installation.
of adhesive on mating surfaces. Try
to keep adhesive out of the rivet
(7). Comply with the following procedures if
holes.
using the Epoxy Adhesive Patch
Method. (e). Install the patch on the panel with
clecos.
(a). Lightly abrade mating surfaces with
emery cloth (CM804) and clean with (f). Rivet the patch to the panel.
surface cleaner (CM228). (g). Wipe excess adhesive from bond line
and from around the rivets.
(b). Air dry for 30 minutes at ambient
temperature. Apply adhesive (h). Allow the panel to cure for 24 hours
(CM411) within 2 hours of drying. prior to installation.
Page 214
Revision 23 253000
MAINTENANCE MANUAL
Section
254000
Miscellaneous
Furnishings
MAINTENANCE MANUAL
MISCELLANEOUS FURNISHINGS
1. Crew Compartment Miscellaneous between foot rest and bulkhead for correct
Furnishings Replacement fourpoint contact.
Methods for removal and installation are D. Ash Receiver and Cigarette Lighter Panel
obvious for most miscellaneous furnishing
items. Some maintenance instructions are (1). The cigarette lighter panel may be
provided in the following procedures. removed by releasing four turnlock
fasteners.
Crew compartment furnishings for the 600N
Helicopter are the same as for the 369D/E/FF (2). Disassembly of the cigarette lighter and
500N Helicopters. panel for maintenance purposes is
shown in the figure.
A. Stowage Box
2. Passenger Compartment Miscellaneous
Access to stowage box is thru crew compart- Furnishings Replacement
ment right side floor access door (Ref. Sec.
525000). Methods for removal and installation are
obvious for most miscellaneous furnishing
items. Some maintenance instructions are
Consumable Materials provided in the following procedures.
Item Nomenclature Passenger compartment furnishings for the
600N Helicopter are the same as for the
CM117 Grease 369D/E/FF 500N Helicopters except, where
applicable, panels and ducting is 30 inches
NOTE: Helicopters equipped with certain op- longer.
tional communications and avionics instal- A. Convenience Panel Replacement (R/H
lations do not have stowage box installed. Command)
When installing replacement stowage box, (1). Remove attachment screws. Lower
cover screwheads with tape (CM717). panel and disconnect any wiring and
heat valve connectors before removing
B. Heat Duct panel.
The heat duct consists of an upper and lower (2). Reinstall using reverse procedure.
section with a magnetic compass mounted on
the lower section just above the instrument 3. Passenger Step Assembly Description
panel. The antiicing control (Ref. Sec.
751000) and cabin heat control (Ref. Sec. (Ref. Figure 203) Due to the extended fuselage
214000) mount on the upper section of the of the 600N Helicopter, the addition of an
heat duct. Removal of magnetic compass is not elongated passenger step is unique to this
required for removal of heat duct. However, aircraft. The step is secured at two positions
wiring to the light must be disconnected at the on each side of the fuselage, as compared to
splices. one position on the 369D/E/FF 500N
Helicopters. The step is available in either a
C. Foot Rest (L/H Command) high or low step configuration depending on
the landing gear option installed.
For access to foot rest attaching hardware,
remove stowage box. Position replacement foot 4. Passenger Step Assembly Inspection
rest on floor support bulkhead and install
attaching hardware. When necessary, use (1). Inspect step attach point(s) for security
additional thin aluminum washers to shim of installation and general condition.
Page 201
254000 Revision 23
MAINTENANCE MANUAL
(2). Inspect "no skid" surface of step for

general condition. Replace or reattach if Consumable Materials
worn excessively. (Ref. Section 910000)
Item Nomenclature
5. Passenger Step Assembly Replacement
CM724 Tape, nonslip
A. Passenger Step Assembly Removal

(1). To replace worn or lost safetywalk
(1). Gain access to passenger step assembly tape, carefully scrape away damaged
attaching hardware under floor cover- tape. Remove all residual adhesive by
ing of passenger/cargo compartment. wiping with naphtha (CM220) wetted
cloth.
(2). Remove quick release pin(s) that secure (2). Install new tape (CM724) and press
step assembly in mounting hole(s). firmly into place. Expel air bubbles by
pressing down tape from center out to
the edges.
(3). Remove step assembly.
7. Miscellaneous Furnishings Inspection
B. Passenger Step Assembly Installation
(1). Inspect for cracks, breaks or other
unserviceable condition.
(1). Align and insert passenger step
assembly into mounting hole(s) in (2). Inspect helicopter checklist and
fuselage. magnetic compass card for condition
and legibility.
(2). Insert quick release pin(s) to secure (3). Inspect for loose, damaged or missing
step assembly. rivnuts and other attaching hardware
as applicable.
(3). Secure floor covering in passenger/cargo
compartment. 8. Miscellaneous Furnishings Repair
(1). Repair cracks or breaks in thermoplas-
6. Passenger Step Assembly Repair tic material (Ref. Sec. 203000,
Boltaron Trim Panels Repair).
The passenger step has black, nonslip, (2). Perform weld and rivet repairs accord-
pressuresensitive, safetywalk tape applied ing to FAA AC 43.131A, Aircraft
to the upper surface of the step plate. Inspection and Repair.
Page 202
Revision 23 254000
MAINTENANCE MANUAL
SWIVEL BRACKET
VNE CARD
VNE CARD HOLDER
OUTER BOX
ANTIICING CONTROL
(6)
UPPER SECTION
CABIN HEAT CONTROL LOCKING PIN
(NOTE 1)
LOWER SECTION
JACKING
END CAP FITTING
(4)
STEP SUPPORT SHAFT
MAGNETIC COMPASS
(10)
HEAT DUCT AND MAG-

NETIC COMPASS
CREW COMPARTMENT
STOWAGE BOX
PASSENGER COMPARTMENT STEP
NOTES:
1. OPTIONAL EQUIPMENT, (REFER TO
APPLICABLE OPT EQPT MANUAL.) G2540011A
Figure 201. Miscellaneous Furnishings (369D) (Sheet 1 of 2)
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254000 Revision 23
MAINTENANCE MANUAL
MAP POCKET
MAP CASE TRIM

COVER
MAGNETIC COM- HELICOPTER

PASS CARD CHECK LIST
COMPASS CARD AND CHECK LIST
(2)
ASHTRAY
CIGARETTE LIGHTER
BONDED
(2 PLCS)
RECORD HOLDER ASHTRAY PASSENGER COMPARTMENT
FLOOR SUPPORT
BULKHEAD
ASHTRAY
HOLDER
BULKHEAD COVER LIGHTER

(NOTE 2)
(4)
FOOT REST ASHTRAY CREW COMPARTMENT
NOTES: (CONT)
2. NOTE USED WHEN STROBE LIGHTS
POWER SUPPLY OF NIGHT LIGHTING
SYSTEM IS INSTALLED. G2540012A
Figure 201. Miscellaneous Furnishings (369D) (Sheet 2 of 2)
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Revision 23 254000
MAINTENANCE MANUAL
SWIVEL BRACKET
VNE CARD
COVER
VNE CARD HOLDER
ANTIICING CONTROL
(SIX PLCS) (10 PLCS)
CABIN HEAT
CONTROL
LOWER SECTION UPPER SECTION
LOCKING PIN
MAGNETIC COMPASS
CREW COMPARTMENT
STOWAGE BOX
HEAT DUCT AND MAGNET-

IC COMPASS
JACKING
FITTING
STEP SUPPORT SHAFT
PASSENGER COMPARTMENT STEP

(369D/E/FF 500N)
NOTE: INTERIOR FURNISHINGS COM-

MON TO 369D/E/FF 500/600N HELICOP-
TERS EXCEPT WHERE NOTED. G2540021A
Figure 202. Miscellaneous Furnishings (369E/FF 500/600N) (Sheet 1 of 2)
Page 205
254000 Revision 23
MAINTENANCE MANUAL
MAP CASE TRIM

COVER
HELICOPTER
CHECK LIST
MAGNETIC COMPASS CARD
MAP POCKET
BONDED COMPASS CARD AND CHECK LIST

(2 PLCS)
RECORD HOLDER
FLOOR SUPPORT BULKHEAD
LIGHTER
BULKHEAD COVER
(NOTE)
FOOT REST ASHTRAY
NOTE: NOT USED WHEN STROBE

LIGHTS POWER SUPPLY OF NIGHT ASHTRAY CREW COMPARTMENT
LIGHTING SYSTEM IS INSTALLED. G2540022A
Figure 202. Miscellaneous Furnishings (369E/FF 500/600N) (Sheet 2 of 2)
Page 206
Revision 23 254000
MAINTENANCE MANUAL
QUICK
RELEASE PIN
4 PLCS
(TYP)
6G25080
Figure 203. Passenger Step Assembly (600N)

254000 Revision 23
MAINTENANCE MANUAL
Section
255000
Cargo Hook
MAINTENANCE MANUAL
CARGO HOOK
FAULT ISOLATION
1. Cargo Hook Description located on the left side of the hook body.
Regardless of the method used to release the
The cargo hook provides a means of transport- hook, the hook will return to the closed
ing external cargo. The cargo hook installation (retracted) position.
consists of a cargo hook assembly, electrical
hook release equipment and backup emergen- 3. Cargo Hook Fault Isolation
cy manual release equipment. The cargo hook
assembly is externally attached to the center (Ref. Table 101) Cargo hook system malfunc-
beam of the helicopter at Station 99.325. The tions might be caused by any one of several
cargo hook operational rating (external load general conditions which are easily corrected.
limit) is 2000 pounds. Before starting specific troubleshooting
procedures, make the following checks and
The cargo hook and swivel assembly are take indicated action for troubleshooting
mounted on the helicopter center beam by four procedures.
bolts at Station 99.325. The swivel assembly
allows the cargo hook to swing in any direction (1). Refer to applicable wiring diagram and
through a 30degree arc. check for loose or damaged wires and/or
terminals and connectors; reconnect or
2. Cargo Hook Operation replace as required.
The cargo hook is normally operated electrical- (2). Check for damaged interconnect wires
ly by pressing the CARGO HOOK switch on and/or equipment (Ref. Chap. 96).
the pilots cyclic stick grip (Ref. Figure 403). (3). Check for loose or defective terminal
Actuation of the CARGO HOOK switch board connections; repair or replace as
energizes a solenoid in the cargo hook. The required.
maximum electrical current required to
operate the cargo hook solenoid is 14 amperes (4). Check for loose ground wires.
at 28 Vdc. however, the solenoid is designed to
operate with voltage as low as 23 Vdc. Actua- (5). Make certain circuit breaker is pushed
tion of the cargo hook solenoid releases the to full in (closed) position.
hook (load beam). (6). Check system power source.
In the event of an electrical malfunction, the 4. Wiring Diagrams
hook can be released (opened) by pulling a
manual release cable lever attached to the (Ref. Figure 101) Wiring diagrams of the
pilots cyclic stick (Ref. Figure 401). The various cargo hook electrical system circuits
manual release cable releases (opens) the have been illustrated. Wire charts are provided
cargo hook in the same manner as the electri- in Table 102 and Table 103. For helicopter
cally operated solenoid. The hook can be electrical system interface information refer to
released for testing or by cargo personnel by DC Electrical Load Distribution (Ref. Chap.
turning (clockwise) a cargo hook release knob 96).
Page 101
255000 Revision 23
MAINTENANCE MANUAL
Table 101. Troubleshooting Cargo Hook Installation

NOTE: Following procedures are to be performed with electrical system power on and CARGO HOOK circuit
breaker (CB603) closed.
Hook release operates manually (by Defective hook ground Replace hook assembly.
lever) but fails to operate electrically
(by HOOK RELEASE switch). Defective ground Secure ground wire.
Defective HOOK RELEASE switch Replace switch.
Defective CARGO HOOK circuit Replace circuit breaker (CB603).

breaker (CB603)
Hook release operates electrically Manual release cable housing Reset adjustment nut at leverend
(by HOOK RELEASE switch) but adjusted incorrectly at lever. of cable housing.
fails to operate manually (by lever).
Defective hook assembly Replace hook assembly.
Table 102. Wire Chart, 369D/E/FF Right or Left Hand Command.

From To
Wire No.* Terminal Termination Terminal Termination
M532A20 TB118D MPCM20MH2** K104X1 Solder
TB119B MPCM20MH2** K104X1 Solder
M531A16 TB31D AYH11H1** K104D2 Solder

M523A20N J104X2*** Solder E24 MS25036103
M522C16 K104D1*** Solder TB34A AYH14H1**
M520AA16 SP92B 32447 TB31C AYH14H1**
J616q Crimp TB31C AYH14H1**
M520A16 CB6032 MS25036106 SP92A 32447
CB6032 MS25036106 P616q
M520B20 TB118C MPCM20MH2** TB31D AYH14H1**
TB118A MPCM20MH2** TB31D AYH14H1**
TB119A MPCM20MH2** TB31D AYH14H1**
*(Ref. Figure 101 sheets 1 & 2) for applicable wiring diagrams.

**Burndy Corp., Norwalk, Conn.
***K312X2, _D1 for helicopters equipped with 369D24153 Tee console.
Page 102
Revision 23 255000
MAINTENANCE MANUAL
Table 103. Wire Chart, 369E/FF TPanel with Center Electrical Console, R/H Command.
From To
Wire No.* Terminal Termination Terminal Termination
M520AA16 K104X2 Solder E24 MS25036103
M532A20 K104X1 Solder TB18F M39029/22192
M531A16 K104D2 Solder TB31C M39029/22193
M531B16 K104D1 Solder TB38B M39029/22193
M520B20 TB31E M39029/22193 TB18E M39029/22192
M523C20N J605C MS3193A1616A E20 M7928/124
M520A16 CB1182 M7928/141 P616 Q M39029/31228
M520AA16 J616 Q M39029/32247 TB31 M39029/22193
*(Ref. Figure 101 sheet 3) for applicable wiring diagram.
Page 103
255000 Revision 23
MAINTENANCE MANUAL
P605J
TB34 TB118
A M522D16 A M522C16 M523A20 D
B C
TB31
C M523B16N E20
K104 M531A16 D M520B20 SP92
M523BB20
C M520AA16 B A
CARGO HOOK D1 D3 D2
X1
C1 C3 C2 CB603
CR3 1 2
369D STANDARD CYCLIC STICK GRIP B1 B3 B2 M520A16
HOOK RELEASE 15A
31149, 11511184 X2 SWITCH (S114)
A1 A3 A2 P130J
1020 A M522A20
E24 M523A20N 920 B M521E20
P605J
TB34 TB118
A M522D16 A M522C16 M523A20 D
B A
TB31
C M523B16N E20
K104 M531A16 D M520B20 SP92
D1 D3 D2 C M520AA16 B A
CARGO HOOK
X1
C1 C3 C2 CB603
CR3 1 2
369D OPTIONAL CYCLIC STICK GRIP B1 B3 B2 HOOK RELEASE M520A16
15A
RIGHT OF LEFT HAND COMMAND X2 SWITCH (S4)
A1 A3 A2 P130J
1020 E M520C20
E24 M523A20N 920 A M522A20
P605J NOTE 1
TB34 TB119
A M522D16 A M522C16 M523A20 B
B A
TB31
C
M523B16N E20 M531A16 D M520B20
K104 J616P
M523BB20
C M520AA16 q
CARGO HOOK D1 D3 D2
X1
C1 C3 C2 CB603
CR3 1 2
369D RIGHT HAND COMMAND B1 B3 B2 M520A16
HOOK RELEASE 15A
CYCLIC STICK GRIP X2 SWITCH
31149, 11511184 A1 A3 A2 P109J
WHT/VIO
OR BLUE D M521F20
E24 M523A20N WHT/GRAY E M520F20
NOTES: OR GRAY
1. 369D294402 CENTER ELECTRICAL CONSOLE:
703 WITH ARMAMENT PANEL P109J TB119
701 WITHOUT ARMAMENT PANEL B M521F20 C NOTE 2
2. 369D294500 CENTER ELECTRICAL CONSOLE A D
M520F20
WITH VHFFM RADIO SET AND ASW EQUIPPED
HELICOPTERS. G2550051
Figure 101. Cargo Hook Wiring Diagrams (Sheet 1 of 4)
Page 104
Revision 23 255000
MAINTENANCE MANUAL
CARGO HOOK RE- J130P TB112

LEASE SWITCH A J109A (REF)
10 OR BLU A M522A20 B
S4 C J109B (REF)
9 OR GRY B M521E20 D M520B20
M532A20 TB31 J9P

K104 C M520AA16 l
D
D1 D3 X1 D2 M531A16
C1 C3 C2
CR3 CB603
B1 B3 B2 E24 1 2
15A M520A16
A1 A3 X2 A2
M523A20N CARGO HOOK RELEASE
TB34 P605J
M522C16 A M522D16 A BLK
M523BB20N C
369D CYCLIC STICK GRIP
LEFT OR RIGHT HAND COMMAND E20 M523B16N B WHT
1150, 11851204
E24 TB112
K312
C
A1 A3 A2 A
X2 M523A20 D
B1 B3 B2 M520B20 B
CR3
C1 C3 C2
J9P
X1
D1 D3 D2 M531A16 D C M520AA16 l
TB31
CB603
1 2
M531B16 15A
J605P HOOK RELEASE

SWITCH (PILOTS) M520A16
A M522D16 A S4 J130P
B TB34
C M523C20N A M522A20
B M521E20
HOOK RELEASE
SWITCH (COPILOTS)
CARGO HOOK E20 S4 J109P
ASSEMBLY
A M522C20
369E/FF CYCLIC STICK GRIP B M521G20
LEFT OR RIGHT HAND COMMAND
G2550052
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255000 Revision 23
MAINTENANCE MANUAL
P616J TB31 PILOT

CB118
J109P S4
REF 1 M520A16 Q M520AA16 A
15A 2 TB18 M522C20 A
M531A16 C M521G20 B
E B
E M520B20 COPILOT
F C J130P S4
X1
M532A20 L H M522A20 A
M J M521E20 B
CR3
X2
M523A20N
A1 E24
A2
A3
B1 16 AWG BUS WIRE
B2
B3
C1
C2
C3 TB38 J605P
D1
D2 M531B16 B A M522D16 A
D3 M523B16N B
M523C20N C
K104
HOOK
369E/FF RIGHT HAND COM-
MAND CONFIGURATION
E20
G2550053
HOOK ASSY
CB603 P/J1202 J/P605
15A
M1015A16 C M1015B16 M1015C16 A
1 2
M1105A22
M1107A22 M1020A16N B
K201 X1 M1021A20N C
HOOK RELAY
X2 E36
B M1179A22N
E37 B
Y D J109 P109
Z 2M1106B22 B B 9 S4
2M1106A22 A A 10 HOOK
P130 J130 W
(RIGHT COLLECTIVE GRIP)
S4 9 B B 1M1106B22 T
HOOK 10 A A 1M1106A22 TB2004
(LEFT COLLECTIVE GRIP)
N
P
R
EFFECTIVE 369E 384 & SUBS
S AND 369FF 076 & SUBS
TB2004 G2550054
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Revision 23 255000
MAINTENANCE MANUAL
CARGO HOOK
1. Cargo Hook Replacement cable, installation and adjustment of the
manual release lever as follows:
A. Cargo Hook Removal
(1). Secure base of cargo hook assembly
Remove the cargo hook assembly including the (Ref. Figure 404) to fuselage underside
cargo hook manual release cable and electri- with bolts and washers.
cal harness as follows:
(2). Remove protective cap from cargo hook
(1). Remove cotter pin (Ref. Figure 405), electrical receptacle (J605); check that
washer, and slotted bushing from BATTERY switch is in OFF position
manual release lever on pilots cyclic and connect plug (P605) to receptacle.
stick. (3). Insert free end of hook manual release
cable through elongated hole adjacent
(2). Loosen locking nut securing adjustment
to electrical receptacle (Ref.
nut shaft to release lever bracket.
Figure 402). Push manual release cable
(3). Remove screws (Ref. Figure 401), nuts, up into fuselage and insert cable
washers, and clamps securing manual through hole in pilots floor.
release cable to cyclic stick. (4). Loosely attach harness and manual
release cable using clamps (Ref.
(4). Remove adjustment nut shaft (Ref.
Figure 402) screws, washers, and nuts.
Figure 405) from release lever bracket.
Adjust harness and cable to allow
(5). Loosen dust cover from pilots cyclic sufficient slack for hook to swing 30
stick control trim cover (Ref. Sec. degrees conically from centerline
253000). without creating strain on harness and
cable. Arrange harness and cable to
(6). Remove passenger/cargo compartment form smooth flow to cutouts in fuselage
left foot fairing trim (Ref. Sec. skin; tighten clamps. Install tie straps
253000). approximately as shown (Ref.
Figure 402).
(7). Carefully push manual release cable
(Ref. Figure 401) down through grom- NOTE: The 600N helicopters equipped with
mets in pilots floor and fuselage skin. emergency floats require the manual re-
Do not pull on cable housing. lease handle to be mounted on the collective
stick (Ref. Figure 406).
(8). Remove cargo hook electrical harness
(5). Loosely attach manual release cable to
plug from receptacle in fuselage; install
cyclic stick with clamps, screws,
protective caps on receptacle and plug.
washers, and nuts (Ref. Figure 401).
(9). Remove clamps (Ref. Figure 402) (6). Engage approximately half of the
securing cable and harness to clips on threads on the manual release cable
fuselage underside. adjustment nut shaft into the bracket
portion of the manual release lever
(10). Remove four bolts (Ref. Figure 404)
assembly (Ref. Figure 405).
securing cargo hook base to attach
holes in fuselage keel. (7). Engage swaged ball on release cable in
lever bushing (Ref. Figure 405). Secure
B. Cargo Hook Installation bushing with washer and cotter pin.
Installation of the cargo hook kit consists of (8). Attach manual release lever assembly
attaching the hook, and electrical/manual to cyclic stick with clamp and screws.
release cables on the underside of the helicop- Adjust cable and/or release lever as
ter, routing and securing the manual release shown (Ref. Figure 405).
Page 401
255000 Revision 23
MAINTENANCE MANUAL
(9). Tighten three sets of clamps securing (12). Install grommet (Ref. Figure 401) in
release cable to cyclic stick. crew compartment floor cutout.
(10). Perform adjustment/test of cargo hook (13). Install grommet (Ref. Figure 402) in
installation. elongated hole in fuselage lower skin
(11). Readjust cable lever (Ref. Figure 405) and doubler.
as required to obtain smooth consistent
release of hook. (14). Safetywire manual release lever clamp
screws with lockwire (Ref. Figure 405).
NOTE: The manual release lever clamp may be
loosened and the lever assembly moved on
cyclic stick to simplify adjustment, provid-
ing the 2.250 0.250 inch (5.715 0.635 cm)
dimension limit is maintained (Ref.
Figure 405).
Page 402
Revision 23 255000
MAINTENANCE MANUAL
CLAMP CLAMP
SCREW
NUT
HOOK RELEASE DECAL (NOT REQUIRED WASHER
WITH OPTIONAL EQUIPMENT GRIP)
CARGO HOOK CLAMP INSTALLATION

EMERGENCY RE- (TYP THREE PLACES)
LEASE DECAL
PILOTS CYCLIC STICK
CANTED STATION 64.365
CREW COMPARTMENT FLOOR
GROMMET
MANUAL RELEASE CABLE
ELECTRICAL RECEPTACLE (J605)
FUSELAGE SKIN LINE
ELECTRICAL PLUG (P605)

STA 63
G255000
Figure 401. Manual Release Cable Routing Interior
Page 403
255000 Revision 23
MAINTENANCE MANUAL
CARGO HOOK

AND ELECTRICAL HARNESS
STATION
99.325
NOTE 4
BUTT LINE 00
(CENTERLINE)
5.5 0.5 INCHES
11.5 0.5 INCHES STRAP (NOTE 3)

CREW COMPARTMENT ELECTRICAL WIRE HARNESS
FLOOR
STRAP
FUSELAGE
GROMMET
SKIN LINE STATION
84.79
STRAP
CANTED STATION 78.50
ELECTRICAL EXTERIOR ATTACHMENT OF MANUAL WASHER

RECEPTACLE RELEASE CABLE AND ELECTRICAL
WIRE HARNESS CLAMP (ELECTRICAL)
CLIP
NOTES:
1. LEFT HAND COMMAND ILLUSTRATED. RIGHT HAND COMMAND CLAMP
DIMENSIONS THE SAME EXCEPT ON OPPOSITE SIDE. NUT (MANUAL)
2. EXISTING RIVET LOCATION AT STATION 84.79.
3. P4 HUCK RIVET MAY BE USED INSTEAD AT STATION 84.79.
4. HARNESS AND CABLE TIED TOGETHER MIDWAY BETWEEN SCREW
STATION 84.79 AND HOOK ASSEMBLY. RIVET (NOTES 1, 2)
5. MAINTAIN SUFFICIENT SLACK IN NOTED SECTION OF CABLE
AND HARNESS TO ALLOW HOOK TO SWING 30 DEGREES
CONICALLY FROM CENTERLINE WITHOUT CREATING STRAIN
CLAMP ATTACHMENT
ON CABLE AND HARNESS. (TYPICAL) G255001
Figure 402. Manual Release Cable and Electrical Wire Harness Routing Exterior
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Revision 23 255000
MAINTENANCE MANUAL
CARGO HOOK RELEASE

CIRCUIT BREAKER
369D LEFTHAND
COMMAND CONFIGURATION
CARGO HOOK RELEASE
CIRCUIT BREAKER
369E/FF "TEE" PANEL

LEFTHAND COMMAND CONFIGURATION
HOOK RELEASE DECAL CIRCUIT BREAKER PANEL
CARGO HOOK RE-

LEASE SWITCH CARGO HOOK RELEASE RIGHTHAND COMMAND
CIRCUIT BREAKER WITH CENTER ELECTRICAL
CONSOLE CONFIGURATION
REMOVE PLUG BUTTON
AND INSTALL CARGO
HOOK RELEASE SWITCH
STANDARD GRIP
HOOK RELEASE DECAL
CARGO HOOK RE- OPTIONAL

LEASE SWITCH "T" GRIP
HOOK RELEASE SWITCH

OPTIONAL
EQUIPMENT
GRIP PILOTS CYCLIC STICK GRIP
G255002
Figure 403. Cargo Hook Electrical Equipment Installation
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255000 Revision 23
MAINTENANCE MANUAL
DECAL
DECAL
FUSELAGE LOWER
SKIN SURFACE
NEOPRENE PAD
0.090 X 1.75 X 4.0 IN.
(0.229 X 4.445 X
10.16 CM) (NOTE)
NEOPRENE PAD
0.090 X 1.75 X 1.75
WASHER (4 PLACES) IN. (0.229 X 4.445 X
4.445 CM) (NOTE)
BOLT (4 PLACES)
EXTERNAL RELEASE
(TURN CLOCKWISE)
ELECTRICAL WIRE
HARNESS
SWIVEL
STA 99.325
KEEPER
1.62 0.12 IN.

MANUAL RELEASE CABLE (4.1148 0.3048 CM) 1.12 0.12 IN.
HOOK (LOAD BEAM) 1.00 0.12 IN. (2.8448 0.3048 CM)
(2.54 0.3048 CM)
LONGITUDINAL
CENTERLINE OF
FWD 4HOLE LAYOUT
1.88 0.12 IN. (4.7752 0.3048 CM)
2.00 0.12 IN.
(5.08 0.3048 CM)
3.75 0.12 IN.

(9.525 0.3048 CM)
(2 PLCS)
LATERAL CENTERLINE
NOTE:
OF 4HOLE LAYOUT
PADS PREVENT FUSELAGE SKIN DAM-
AGE AT HOOK CONTACT POINTS.
G255003A
Figure 404. Hook and Pad Installation
Page 406
Revision 23 255000
MAINTENANCE MANUAL
20 (NOTE 2)
CARGO HOOK MANUAL RE-
LEASE LEVER ASSEMBLY
SLOTTED BUSHING
(NOTE 5)
CARGO HOOK
RELEASE CABLE
2.250 0.250
INCHES
POSITIONING LEVER ON STICK

CLAMP
LOCKWIRE
HOOKENGAGED LEVER
POSITION (NOTES 3, 6)
LOOKING AFT AND DOWN

CARGO HOOK
RELEASE LEVER
BALL TERMINAL COTTER PIN

(NOTE 1)
LOCKING NUT
(NOTE 4) WASHER
NOTES:
1. CABLE BALL TERMINAL RETAINED IN SLOTTED BUSHING OF RELEASE LEVER.
2. APPROXIMATE ANGULAR POSITION OF LEVER REQUIRED FOR
CONVENIENCE AND RELEASE OF CARGO HOOK.
3. CABLE BALL TERMINAL AFT TRAVEL SHOULD BE APPROXIMATELY ADJUSTMENT
1/2 INCH TO RELEASE HOOK. NUT (NOTE 4)
4. WITH LOCKING NUT LOOSENED, TURN ADJUSTMENT NUT TO PULL RELEASE RELEASE
LEVER TO FULL FORWARD (HOOK ENGAGED) POSITION WITH SLIGHT BRACKET
TENSION ON CABLE; TIGHTEN LOCKING NUT. IF REQUIRED, ADJUST
POSITION OF LEVER ASSEMBLY ON CYCLIC STICK. LOOKING INBOARD FROM
5. BUSHING 369H92631 MAY BE USED AS ALTERNATE. LEFT SIDE OF HELICOPTER
6. LEVER SHOULD NOT MOVE FROM HOOKENGAGED POSITION WHEN
CYCLIC STICK IS MOVED THROUGH FULL TRAVEL IN ALL DIRECTIONS. G255004
Figure 405. Cargo Hook Manual Release Lever Installation
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255000 Revision 23
MAINTENANCE MANUAL
CARGO HOOK MECHANI-

CAL RELEASE
CARGO HOOK ELEC-

TRICAL RELEASE
CYCLICMOUNTED electrical hook release

CARGO HOOK
RELEASE CABLE
STANDARD CYCLICMOUNTED mechanical hook release
CARGO HOOK MECHANICAL RELEASE
CARGO HOOK RELEASE CABLE
collectiveMOUNTED mechanical hook release (note)
NOTE: for 600N MODEL helicopters equipped with the optional emer-
gency float installation, stc# sr00471la.
600521
Figure 406. Cargo Hook Release for 600N Helicopters
Page 408
Revision 23 255000
MAINTENANCE MANUAL
CARGO HOOK
INSPECTION/CHECK
1. Cargo Hook Operational Check Cargo hook must remain
WARNING closed while moving
Perform the following operational check through all positions of extreme travel
procedure whenever it is necessary to verify fore and aft as well as sidetoside.
that the cargo hook system is operating (8). Grasp load ring and pull downward
properly: while moving cargo hook manually full
travel sidetoside. Ensure hook (load
(1). Place battery switch in BATTERY beam) remains in locked position.
position.
2. Adjustment
(2). Check that CARGO HOOK/HOOK Adjust the manual release cable so that the
circuit breaker is pressed to full in 2.250 0.250 inch (5.715 0.635 cm) dimension
position (Ref. Figure 402). shown (Ref. Figure 405) is maintained.
NOTE: Cargo load rings (or equivalent check 3. Exterior Components Inspection
tool) with a maximum crosssection thick- On cargo hooks, manufac-
ness of 3/4 inch can be used for testing or for WARNING tured by BreezeEastern,
cargo transport operations. Model 2A20B, P/N 171491 thru 5, en-
sure Warning Plate P/N 138301 is at-
(3). Push cargo load ring forward into hook tached to the manual release side of the
throat (Ref. Figure 404); keeper should cargo hook. If Warning Plate is not
permit easy entrance to hook throat. installed, contact BreezeEastern for
Warning Plate and installation instruc-
(4). Pull aft and downward on load ring; tions.
hook must remain in locked position.
(1). Make certain that neoprene pads (Ref.
(5). Rotate external release knob located on Figure 404) are securely bonded to skin.
left side of cargo hook body, while Check pads for excessive wear.
pulling downward on load ring; hook (2). Verify security of four bolts attaching
(load beam) bar should drop and release hook assembly to fuselage (Ref.
load ring. Figure 404); examine hook assembly for
damage or excessive wear. Check that
(6). Reinsert load ring in hook throat. Pull hook body swivels freely in all direc-
CARGO HOOK EMERGENCY RE- tions.
LEASE (manual release) lever on pilots
cyclic stick while load ring is being (3). Verify security of clips and clamps
pulled downward; hook (load beam) attaching electrical wire harness and
should release load ring. Reinsert load manual release cable housing to
ring and move pilots cyclic stick to all fuselage (Ref. Figure 402).
extreme positions; CARGO HOOK (4). Verify presence and security of grom-
EMERGENCY RELEASE lever must met (Ref. Figure 401) through which
not move from hookengaged position manual release cable passes at fuselage
and hook load beam must remain in skin.
locked position.
(5). Check electrical wire harness for cuts,
wear, and skinned insulation.
(7). Press CARGO HOOK switch on pilots
cyclic stick grip (Ref. Figure 403) while (6). Examine manual release cable housing
load ring is being pulled downward; for nicks, cuts, kinks, dents, or general
hook load beam should release load damage that would restrict movement
ring. of cable within housing.
Page 601
255000 Revision 23
MAINTENANCE MANUAL
4. Interior Components Inspection NOTE: The 600N helicopters equipped with

emergency floats require the manual re-
lease handle to be mounted on the collective
(1). Verify security of electrical receptacle
stick (Ref. Figure 406)
(J605) at fuselage connection (Ref.
Figure 401). (6). Verify security of clamps attaching
manual release cable housing to pilots
(2). Examine electrical wire harness for cyclic stick (Ref. Figure 401); check for
cuts, wear, or skinned insulation. damage to manual release cable
housing that might restrict movement
of cable.
(3). Check manual release cable housing for
nicks, cuts, kinks, dents, or general (7). Check security of manual release lever
damage that would restrict movement attachment to pilots cyclic stick (Ref.
of cable within housing. Figure 405).
(8). Examine decals (Ref. Figure 403) for
(4). Verify presence and security of grom- secure attachment and legibility.
met where manual release cable passes
through pilots floor (Ref. Figure 401). (9). Examine cargo hook circuit wiring for
damage and/or loose connections.
(5). Check security of manual release cable (10). Verify secure installation of CARGO
housing adjustment nut; verify that HOOK circuit breaker and HOOK
release lever freely returns to hooken- RELEASE pushbutton switch (Ref.
gaged position (Ref. Figure 405). Figure 403).
Page 602
Revision 23 255000
MAINTENANCE MANUAL
CARGO HOOK
1. Cargo Hook Initial Installation NOTE: Fuselage cutouts for left and right hand
command are as illustrated (Ref.
Procedures in this section may be performed at Figure 901). Use applicable dimensions ac-
the operators discretion and are applicable to cording to the model helicopter being modi-
369D/E/FF 500N helicopters. These instruc- fied.
tions provide for the installation of the cargo
hook assembly. (1). Make cutouts in three places as
illustrated (Ref. Figure 901).
A. Preparation for Installation
Preparation for installation of the cargo hook Consumable Materials

assembly includes the following: (Ref. Section 910000)
Item Nomenclature
(1). Identify all components, including CM318 Primer
attaching hardware, or components to
be removed for access to work areas.
Protect components from damage and (2). Deburr cutouts and apply thin coat of
contamination until installed. primer (CM318) to exposed bare metal.
(2). Check that all electrical switches are in D. Cargo Hook Provisions Installation
OFF position.
(Ref. Figure 404) The following procedure
(3). Make certain BATTOFFEXT switch involves installation of the cargo hook provi-
is in OFF position. sions exclusive of the cargo hook assembly kit.
To complete installation of the cargo hook
B. Helicopter Equipment Removal system, both cargo hook provisions, and the
cargo hook assembly kit installations must be
(Ref. Figure 404) Prior to installing the cargo accomplished. Hook provision equipment
hook, a limited number of items must be omitted in the following procedure is included
removed from the helicopter to accommodate in the cargo hook installation procedure.
cargo hook installation. Install cargo hook provisions as follows:
(1). Remove plug button from cargo switch

hole in stick grip; discard plug button.
(2). Remove passenger/cargo compartment Item Nomenclature
left support fairing. CM206 Chemical coating
(3). Remove passenger/cargo compartment CM230 Paint remover
seat.
CM318 Primer
(4). Remove cyclic stick control cover. CM418 Cement, epoxy
(5). Remove pilots floor left covering.

NOTE: The cargo hook and provision kits are
(6). Remove pilots floor left access door. supplied with as many parts assembled as
practical, however, some parts might re-
C. Modification of Helicopter quire assembly at installation. The operator
should omit those steps which may have al-
Modification of the helicopter consists of ready been accomplished.
cutouts in the pilots floor and fuselage lower
skin to accommodate routing of the cargo hook (1). Install cargo hook neoprene pads as
manual control cable and electrical harness. follows:
Page 901
255000 Revision 23
MAINTENANCE MANUAL
(a). Remove paint from fuselage skin in E. Electrical Components and Wiring
pad installation areas as shown; use Installation (Left and Right Hand
paint remover (CM230). Command)
(b). Clean metal in areas where paint as Consumable Materials

removed; use surface cleaner (Ref. Section 910000)
(CM228). Item Nomenclature
(c). Bond neoprene pads to skin at CM614 Sleeving, heatshrink
locations shown; use adhesive CM704 Tie strap, nylon
(CM418).
NOTE: The order and manner of installation

(2). Prime and touchup border areas
for left or right hand command is the same.
around pads as follows:
Refer to dimensions given in applicable fig-
ures, for model of helicopter being modified.
(a). Wash affected area with solution of
mild soap and fresh water. Rinse (1). Make certain BATTERY switch is in
area with clean water and wipe dry OFF position.
with clean lintfree cloth. (2). Disconnect battery connector.
(b). Using swab, liberally apply chemical (3). Connect cargo hook switch to existing
film (CM206). wires according to stick grip and model
helicopter being modified. Insulate
wires and contacts on switch with
(c). Allow solution to remain on surface sleeving (CM614). Ref. Table 901 and
for 1 to 3 minutes, or until surface applicable wiring diagrams (Ref.
becomes amber to brown in color. Figure 101).
(4). Install switch guard on switch. Apply
NOTE: Avoid letting chemical mixture dry on
small amount of adhesive (CM404) to
surface. If it has dried, rewet surface with
O.D. of switch.
solution.
(5). Install switch in grip. Allow minimum
(d). Rinse treated surface with clean cure time of 24 hours 30 minutes.
water. After rinsing, wipe off excess
(6). Install relay on bracket with screws,
moisture with clean lintfree cloth.
Allow area to dry completely at room
temperature for 1 hour. Table 901. Cargo Hook Relay Installation
(e). Wipe surface clean with thinner and Relay Model Location Remarks
dry off immediately. K104 D 369A2519 Slim console
Bulkhead
(f). Apply primer (CM318) and allow to
dry for 30 minutes. K312 E/FF 369H2500 TPanel
Bulkhead
(g). Apply lacquer to match original (7). Locate existing mounting holes accord-
factory finish color. ing to model of helicopter being modi-
fied. (Ref. Table 902 and Figure 902).
NOTE: Installation of the cargo hook manual Using relay bracket as a template,
release lever assembly and clamp assem- mark and drill attachment hole(s)
blies is accomplished during installation of 0.1650.177 inch (4.1914.4958 mm) in
the cargo hook kit. bulkhead as required.
Page 902
Revision 23 255000
MAINTENANCE MANUAL
STA. 64.365
CREW COMPARTMENT
DOOR
10.00 LBL CHANNEL
GROMMET
PILOTS FLOOR
PILOTS FLOOR
5.00 0.25 IN.
(12.7 0.635 CM)
3.00 0.25 IN.
(7.62 0.625 CM) 0.5550.562 IN.
GROMMET
(14.097014.2748 MM)
HOLE
10.00 RBL
CLIP 0.5550.562 IN.
0.88 IN. 0.88 IN. CHANNEL
(14.097014.2748 MM)
(22.352 MM) (22.352 MM)
HOLE
CREW COMPARTMENT FLOOR CUTOUT CREW COMPARTMENT FLOOR CUTOUT
(LEFTHAND COMMAND) (RIGHTHAND COMMAND)
GROMMET GROMMET LONGERON
12.05 LBL 0.68 X 1.18 IN.

(17.272 X
29.972 MM)
STIFFENER (NOTE 1)
0.68 X 1.18 IN.
(17.272 X
29.972 MM) 0.8900.901 IN.
(NOTE 1) (22.606
22.8854 MM)
12.05 RBL
(NOTE 2)
0.8900.901 IN.
(22.606
22.8854 MM)
(NOTE 2) LONGERON STIFFENER
0.38 IN. 0.38 IN.
DOUBLER (9.652 MM) DOUBLER
(9.652 MM)
DOUBLE INSTALLATION DOUBLE INSTALLATION

(LEFTHAND COMMAND) (RIGHTHAND COMMAND)
NOTES:
1. SLOT IN SKIN TO MATCH SLOT IN DOUBLER.
2. HOLE IN SKIN TO MATCH HOLE IN DOUBLER. G255006A
Figure 901. Fuselage Skin Cutouts
Page 903
255000 Revision 23
MAINTENANCE MANUAL
(8). Attach relay bracket to bulkhead with manual release cables on the underside of the
screws, washers and nuts. Identify helicopter, routing and securing the manual
relay as indicated (Ref. Table 902), release cable, and installation and adjustment
using a suitable contrasting permanent of the manual release lever.
ink.
(1). Secure base of cargo hook assembly to
(9). On left hand command helicopters, fuselage underside with bolts and
remove edgelighted panel from lower washers (Ref. Figure 404).
switch and circuit breaker panel: loosen
lower circuit breaker panel. Remove (2). If installed, remove protective cap from
hole cover button; install circuit cargo hook electrical receptacle (J605);
breaker (CB603) (Ref. Figure 402). check that BATTERY switch is in OFF
position and connect plug (P605) to
(10). On right hand command helicopters receptacle.
with center electrical console, remove
edgelighted panel from circuit breaker (3). Insert free end of hook manual release
panel located on the pilots collective cable through elongated hole adjacent
pitch stick cover; loosen circuit breaker to electrical receptacle; push manual
panel remove hole cover button; install release cable up into fuselage and
circuit breaker (Ref. Figure 402). insert cable through hole in pilots floor
(11). On right or left hand command helicop- (Ref. Figure 401).
ters with standard cyclic stick grip, (4). Install electrical harness and manual
install module and cover on TB3. release cable clamp (provision) clips
(12). Install cargo hook circuit wiring; see with rivets (Ref. Figure 402).
applicable wiring diagram (Ref.
Figure 101). For wire termination and (5). Loosely attach harness and cable
terminal hardware, refer to Table 102. clamps with screws, washers and nuts;
adjust harness and cable to allow
(13). Install cargo hook electrical connector sufficient slack for hook to swing 30
with washer and connector nut. Install degrees conically from centerline
protective cap on receptacle if cargo without creating strain on harness and
hook kit is not being installed concur- cable. Arrange harness and cable to
rent with provisions. form smooth flow to cutouts in fuselage
skin; tighten clamps. Install tie straps
(14). Secure cargo hook circuit wiring with (CM704) approximately as shown (Ref.
tiestraps (CM704) as required. Check Figure 402).
that wires and terminals are not
stressed. (6). Loosely attach manual release cable to
cyclic stick with clamps, screws,
(15). Check all wiring for correct installation
and security of attachment.
(16). Connect battery connector. (7). Engage swaged ball on release cable in
lever bushing; secure bushing with
F. Cargo Hook Installation washer and cotter pin (Ref. Figure 405).
(8). Attach manual release lever assembly
to cyclic stick with clamp and screws;
adjust cable and/or release lever as
Item Nomenclature
shown (Ref. Figure 401).
CM429 Sealing compound, silicone
CM702 Lockwire CRES (9). Tighten three sets of clamps securing
CM704 Tie strap, nylon release cable to cyclic stick.
(10). Check that hook does not release when
The cargo hook installation consists of cyclic stick is moved to extremes in all
attaching the hook and emergency electrical/ directions.
Page 904
Revision 23 255000
MAINTENANCE MANUAL
SCREW
RELAY
2.252.50 IN.
(5.7156.35 CM)
NUT
0.25 IN.
(6.35 MM)
0.1650.177 IN.
(4.1914.4958 MM)
HOLE
WASHER SCREW
WASHER
SCREW
WASHER
NUT WASHER
WASHER
2.03 IN. NUT SCREW

(5.1562 CM)
RELAY
K312 RELAY INSTALLATION
WASHER STA. 44.65 (369E/FF 500N)
NUT K104 RELAY INSTALLATION

(369D)
EXISTING
HOLES
WL 10.00
BL 10.00
G255007A
Figure 902. Relay and Bracket Installation Pilots Floor (369D/E/FF)
Page 905
255000 Revision 23
MAINTENANCE MANUAL
(11). Pull manual release lever; check that (16). Install HOOK RELEASE decal on left
hook load beam opens. Repeat opera- or right hand cyclic stick grip (Ref.
tion several times to ensure proper Figure 403).
release of hook.
(17). Install CARGO HOOK EMERGENCY
RELEASE decal on cyclic stick (Ref.
(12). Readjust cable/lever as required to Figure 405).
obtain smooth consistent release of
hook. (18). Install EXTERNAL LOAD LIMIT 2000
POUNDS decal (Ref. Figure 404).
NOTE: The manual release lever clamp may be
loosened and the lever assembly moved on Table 902. VNE Card Installation
cyclic stick to simplify adjustment, provid-
Part Number Model Effectivity
ing the 2.250 0.250 inch (5.715 0.635 cm)
dimension limit is maintained (Ref. 369D29571 D 003 523
Figure 405). 17, 19
(13). Install grommet in crew compartment 21, 23 D/E D 524 & Subs
floor cutout (Ref. Figure 401). Fill any E 001 & Subs
voids between grommet and cable. Use 369D292588 FF 001 & Subs
sealant (CM429).
(19). Replace VNE card on instrument panel
(14). Install grommet in elongated hole in as applicable (Ref. to Table 903).
fuselage lower skin and doubler (Ref.
Figure 402). Fill any voids between G. Helicopter Equipment Installation
grommet and manual release cable. Use
sealant (CM429). Reinstall equipment initially removed in
reverse order of removal.
(15). Safety manual release lever clamp NOTE: At completion of installation, perform
screws with lockwire (CM702), (Ref. an operational check of cargo hook installa-
Figure 405). tion.
Table 903. Cargo Hook Switch Installations Stick Grip

Part Number Model Remarks
369H90153BSC D/E/FF For models equipped with emergency floats, left or right hand
command (Ref. Figure 403).
3 D/E/FF For models equipped with hoist, left or right hand command
(Ref. Figure 403).
369D27133 D/E/FF Standard grip, left hand command (Ref. Figure 403).
369D297846BSC D Center electrical console, T grip right hand command (Ref.
Figure 403).
3 D Center electrical console, T grip right hand command (Ref.

Figure 403).
369H92805 D Center electrical console, T grip right hand command (Ref.

Figure 403).
Page 906
Revision 23 255000
MAINTENANCE MANUAL
H. Weight and Balance Data Table 904. After installation of the cargo hook
Weight and balance changes resulting from incorporate changes in helicopter weight and
installation of the cargo hook are listed in balance record as instructed.

Weight Arm Moment
Added +6.3 (+2.858) +87.0 (+220.98) +548.1 (+631.48)

255000 Revision 23
MAINTENANCE MANUAL
Section
256000
Emergency First Aid
Kit
MAINTENANCE MANUAL
EMERGENCY FIRST AID KIT

1. Emergency First Aid Kit (3). Kit contents include a direction sheet
and the following eight packaged items:
(Ref. Figure 201) adhesive and plain bandage compres-
(1). The Emergency First Aid Kit uses a ses, iodine, swabs, ammonia inhalants,
plastic case that meets Federal Aviation burn ointment, tourniquet, forceps, and
Regulation (FAR) 27.8530 requirements scissors. The contents of the kit meet or
for fire protection. The kit is installed exceed the requirements of Federal
on the lower right front of the seat Aviation Authority (FAA) Specification
structure in the crew compartment and 121, Appendix A for aircraft with a
centered at right buttline 20.75 just passenger capacity of five persons or
above the pilots floor mold line. It less.
attaches to the station bulkhead with
two parallel velcro pile strips, 1 x 8 2. Emergency First Aid Kit Contents Check
inches (2.54 x 20.32 cm), bonded two
inches (5.08 cm) apart in the horizontal Periodically check kit contents to ensure an
position. Two matching velcro hook adequate supply of medical items. Purchase
strips are bonded across the width of individual items locally. To purchase a
the case back. replacement kit, contact:
(2). The kit is easily detached from its MD Helicopters Inc.,

velcro tape mount by a firm pull on the 5000 East McDowell Road,
handle. The case is opened by offset- Mesa, AZ 85205,
ting the snap fastener. Att: New Parts Sales.
Page 201
256000 Revision 23
MAINTENANCE MANUAL
G256010
Figure 201. Emergency First Aid Kit
Page 202
Revision 23 256000
MAINTENANCE MANUAL
Section
256300
Hoist
Passenger/Cargo
MAINTENANCE MANUAL
HOIST PASSENGER/CARGO
1. Hoist Passenger/Cargo mounted on a support tube attached
with quickrelease pins to three fittings
(Ref. Figure 201) located on the exterior of the fuselage
on either side and above the passenger/
cargo door. The support tube positions
(1). The hoist configuration is installed on
the winch to allow raising and lowering
the right side of L/H command helicop-
the cable between the side of the
ters. The configuration for R/H com-
fuselage and landing gear skid. Two
mand is identical except that the hoist
modified mounting brackets are used to
is installed on the opposite (left) side of
accommodate installation of the winch
the helicopter. The passenger/cargo
on the support tube. The winch incorpo-
hoist assembly consists of an electrical-
rates a disctype brake, housed on the
lyoperated winch mounted on a
end of the hoist drum, which consists of
support tube, a hoist operators safety
springloaded friction plates and an
harness, a passenger door (hold open)
actuating solenoid. The solenoid is
retainer assembly, a passenger door sill
energized to release the brake at the
antichafing bar assembly, a control
same time the motor is energized. Once
pendant, and associated electrical
the control pendant switch is released
equipment. The hoist provides a means
to the off position, the brake solenoid is
for lifting and lowering personnel or
deenergized and the brake sets,
objects weighing up to 300 pounds (136
preventing any possibility of uncon-
kg). The hoist system employs light-
trolled cable payout. Cable up (fullin)
weight, readilyattachable and de-
and down (full out) limit switches are
tachable exteriormounted equipment
incorporated in the winch brake
without using passenger or cargo space
system. When either limit switch is in
in the helicopter. For safety purposes, a
the closed position, the brake solenoid
guillotinetype cable cutting device is
is energized, releasing the brake discs
incorporated in the hoist winch assem-
and allowing the winch drum to rotate.
bly. The hoist function is identical when
Conversely, when either limit switch is
operated from either side of the helicop-
in the open position the brake solenoid
ter.
is deenergized and the winch brake
automatically sets and stops the winch.
NOTE: When the hoist is installed on L/H com-
mand helicopters equipped with emergency
floats, the floats must be in a stowed condi- (3). (Ref. Figure 203) The passenger/cargo
tion during hoisting operations. Emergency door retainer assembly consists of a
floats must be removed from R/H command tubular housing attached with four
before conducting hoisting operations. clamps securing the housing horizontal-
ly across the canted bulkhead in the
(2). (Ref. Figure 202) The weatherproof passenger/cargo compartment. With the
winch consists of a 28 Vdc motor that passenger/cargo door in full open
drives a cable drum to which a 110 foot position, a smaller tube stowed inside
(33.5 M) stainless steel cable with a the tubular housing extends in a
swivel hook is attached. The winch is telescoping effect and engages a bracket
equipped with an automatic brake located on the outboard frame of the
system; up (fullin) and down (full out) door, thus retaining the door in an open
limit stop switches; and an explosive, position. The telescoping tube can be
electricallyactivated guillotinetype used in either end of the tubular
cable cutter for cutting the cable in an housing to hold the left or right passen-
emergency. The hoist assembly is ger/cargo door open as required.
Page 201
256300 Revision 23
MAINTENANCE MANUAL
HOIST
PWR CTR
CYCLIC
STICK
GRIP
LEFTHAND COMMAND HELICOPTERS

SWITCH AND CIRCUIT BREAKER PANEL
DOOR RETAINER
SAFETY
HARNESS
HOIST CTR
369D294566 PANEL
HOIST
CTR PWR
369H92143
PANEL
RIGHTHAND COMMAND HELICOPTERS

HOIST CABLE ANTICHAFING BAR CICUIT BREAKER PANELS
G2560011
Figure 201. Hoist System Components (Sheet 1 of 3)
Page 202
Revision 23 256300
MAINTENANCE MANUAL
WINCH
HANGER
AFT BRACKET
FWD BRACKT
HOOK
WINCH SUPPORT
TUBE
BEARING PIN FITTING
LINK ASSY
FITTING
ELECTRICAL PLUG
HOIST SUPPORT AND ATTACHMENTS

(ROTATED)
FITTING
SAFETY PIN
CABLE ANTISNAG PROVISIONS

(ROTATED) G2560012
Page 203
256300 Revision 23
MAINTENANCE MANUAL
WINCH CONTROL
SWITCH
PENDANT
CABLE CUTTER
SWITCH
CONTROL PENDANT CABLE CUTTER WARNING

SWITCH ACCESS DOOR ASSEMBLY
HOIST
CABLE
CUTTER
SWITCH
UNDER
COVER
PROTECTIVE CAP
RECEPTACLE
(XJ2)
PENDANT CONTROL CONNECTOR WASHER
NUT
RECEPTACLE
(J28)
ELECTRICAL GROUNDING STUD HOIST CONNECTOR

(TYP)
G2560013
Page 204
Revision 23 256300
MAINTENANCE MANUAL
(4). (Ref. Figure 201) An antichafing bar, 2. Preparation for Hoisting Operations
installed just below the passenger/cargo
door sill, prevents the hoist cable from To avoid inadvertent firing of
CAUTION cable cutter, ensure cable cutter
cutting the door frame during hoisting
operations. A hoist operators safety electrical circuits are not energized.
harness. provided with the hoist, is
(1). Connect external electrical power to
connected to the seat belt anchor fitting helicopter.
on the side of the passenger/cargo
compartment opposite the side where (2). Place BATTERY switch in EXT posi-
the hoist is installed. tion.
(3). Open passenger/cargo door; extend and

(5). The hoist system electrical equipment secure door (holdopen) retainer tube.
consists of a hand held electrical
pendant control for use in the passen- (4). Using hoist system control pendant,
ger/cargo or crew compartments to exercise winch by paying out 3 or 4 feet
operate the winch, an emergency cable of cable under approximately 15 pounds
cutter switch on the pilots cyclic stick, (6.8 kg) tension, pulling cable straight
down to avoid rubbing cable on cable
circuit breaker equipment, and asso-
bellmouth. Reverse control and reel
ciated electrical wiring. The pendant cable in. Check that cable winds on
control contains a three position switch, winch drum evenly and that winch
spring loaded to the off position, for operation is smooth and consistent.
raising and lowering the swivel hook, Make certain winch stops automatically
and a guarded switch for cutting the when top of swivel hook pushes against
cable at the winch in an emergency. The winch bumper pad.
pilots cyclic stick cable cutter switch
allows the pilot to cut the hoist cable (5). If installed, remove cable cutter jumper
independent of the pendant control. The wire (Ref. Figure 202).
circuit breakers are mounted on the
lower switch and circuit breaker panel Cable cutter jumper wire
WARNING must be removed to allow
in L/H command, and on the circuit
cable cutter electrical circuit to be
breaker panel located aft of the pilots
completed by switch control, providing
collective stick on R/H command. The instantaneous inflight cable cutting
cable cutter circuits are independently capability should such emergency ac-
protected by a separate loweramper- tion be required.
age circuit breaker located adjacent to
the hoist power circuit breaker. Electri- (6). If winch has not been used for an
cal wiring, plugs, receptacles, and extended period of time, or if cable has
terminals interconnect the various been replaced, perform an operational
electrical components. check (Ref. Hoist System Operational
Check).
(6). Differences in hoist installations and (7). Check that winch support tube attach
electrical circuitry for L/H and R/H safety pins are secure and fully seated.
command is described in subsequent
(8). Check that winch electrical connector
text and illustrations. Refer to man-
plug is secure on receptacle on side of
ufacturers publications (Ref. Table 201, fuselage.
Sec. 010000, BL16600 Series 300 Lb
Capacity Hoist Operating lnstructions (9). Connect hoist system operators safety
Hoist Winch Assembly, Breeze Corpora- harness to seat belt fitting on opposite
tion, Inc)) for additional hoist, hook, side of passenger/cargo compartment
cable, and parts information. from where winch is installed.
Page 205
256300 Revision 23
MAINTENANCE MANUAL
WINCH
HOIST SUPPORT
TUBE
DOUBLE HELICAL
SCREW SHAFT
CABLE GUIDE
ASSEMBLY
IDLER GUIDE
ROLLER
TORQUE NUT TO
TRACTION ROLLER 70 100 INCHPOUNDS
(7.91 11.30 NM)
PRESSURE ROLLER
ALLEN HEAD SET SCREW

INDENT
FILLIN (UP)
LIMIT SWITCH
CABLE CUTTER
BELLMOUTH
(GUILLOTINE)
BUMPER RING
PROTECTIVE
ELECTRICAL RUBBER BUMPER
JUMPER PAD
(REF. WARN-
ING)
1/8 IN. (3.175 MM) WARNING: REMOVE JUMPER WIRE AFTER

DIA. CABLE SYSTEM INSTALLATION OR MAINTENANCE
ELECTRICAL (REFER TO TEXT)
GROUND WIRE WIRING
(WHITE, BLUE POSITIVE WIRE (BLACK, CABLE CUTTER CAUTION: CONNECT POSITIVE WIRE ONLY
OR WHITE/BLUE) GREEN, OR WHITE/GREEN) REPLACEMENT (BLACK, GREEN, OR WHITE/GREEN) TO POS-
(REF. CAUTION) ITIVE (+) POST OF CABLE CUTTER.
G2560021A
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement (Sheet 1 of 2)
Page 206
Revision 23 256300
MAINTENANCE MANUAL
RUBBER BUMPER
KEYWAY
HOOK HOUSING
CABLE
SWIVEL HOOK
SOCKET
SWAGED BALL
END FITTING
SAFETY KEEPER
CABLETOHOOK
ATTACHMENT
ROLLER WHEEL TOP COVER

FIRST DRUM GROOVE
FULLOUT (DOWN
LIMIT SWITCH)
CABLE END
(NOTE 1)
ALLEN HEAD SETSCREW
NUT, WASHER
(4 PLCS) (NOTE 1)
HOOK HANGER
(NOTE 2)
CABLE WINDING
(ON DRUM) DRUM
CABLE DRUM FLANGE
CABLE GUIDE ASSEMBLY

DRUM CABLE END
ANCHOR HOLE
CABLETODRUM
ATTACHMENT
NOTES:
1. EXCESSIVE TIGHTENING MAY AFFECT
FULLOUT SWITCH SETTING.
2. USED FOR HOOK STOWAGE. G2560022
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement (Sheet 2 of 2)
Page 207
256300 Revision 23
MAINTENANCE MANUAL
(10). Place BATTERY switch in OFF posi- NOTE: If support tube fittings are to be re-
tion. moved from fuselage, make certain nylon
screws are installed in attachment holes.
(11). Remove external electrical power from
helicopter. (8). Remove bolts securing winch to support
tube brackets.
3. Hoist System Troubleshooting
B. Hoist Assembly Installation
(Ref. Table 201) Wiring diagrams are provided
for the hoist systems used on L/H command Consumable Materials
(Ref. Figure 204) and R/H command helicop- (Ref. Section 910000)
ters (Ref. Figure 205). A schematic diagram of Item Nomenclature
the winch is also provided (Ref. Figure 206).
CM703 Tie strap
(Ref. Chap. 96 for interfacing schematics and
wiring diagrams)
NOTE: If support tube fittings (Ref.
Figure 201) were removed from fuselage, re-
4. Cyclic Stick Grip and Cyclic Stick Cable move nylon screws installed in support fit-
Cutter Switch (S600) Replacement ting attachment holes on fuselage.
(Ref. Sec. 671020) (1). If required, install winch support tube
attach fittings on fuselage using screws
5. Hoist Assembly Replacement and washers.
A. Hoist Assembly Removal (2). Attach winch to support tube using

bolts, washers, and nuts. Torque bolts
(1). Check that cable is fully retracted on to 70 100 inchpounds (7.91 11.30
winch drum. Nm).
(2). Check that BATTERY switch is in OFF (3). Attach link assembly to support tube
position. using bearing pin, washer, and cotter
pin.
(3). Install safety jumper wire on cable
cutter electrical terminals (Ref. (4). Attach winch support tube to fuselage
Figure 202). fittings using quickdisconnect pins.
Protective jumper wire should NOTE: Install pins in positions shown.

CAUTION remain on cable cutter electrical
terminals until winch is reinstalled for use. Check that all electrical power
CAUTION is OFF to eliminate possibility
(4). Disconnect winch electrical plug (Ref. of inadvertent firing of cable cutter.
Figure 201) from receptacle on fuselage;
install protective cap on receptacle. (5). Remove protective cap from electrical
receptacle on side of fuselage. Connect
(5). Support winch; remove three quickdis- winch electrical plug to fuselage
connect safety pins securing winch receptacle. Secure wire harness to
support tube to fittings on fuselage. support tube using tiestraps (CM703).
(6). Remove winch and support tube from Remove protective electri-
fuselage. WARNING cal jumper wire (Ref.
Figure 202) from cable cutter whenev-
(7). Remove cotter pin, washer, and bearing er winch is installed on helicopter.
pin securing link assembly to winch Jumper wire will prevent operation of
support tube. cable cutter in an inflight emergency.
Page 208
Revision 23 256300
MAINTENANCE MANUAL
BRACKET ASSY
(RH)
TUBE
TUBE
RIGHT DOOR BRACKET

(ROTATED)
CLAMP STRUCTURAL RE-

INFORCEMENT
DOUBLER ANGLE BRACKET
CLAMP
RIGHT INBOARD
TUBE CLAMP
RIGHT OUTBOARD
TUBE CLAMP
G256003
Figure 203. Passenger/Cargo Door Retainer Installation
Page 209
256300 Revision 23
MAINTENANCE MANUAL
6. Winch Components Replacement (c). Continue unwinding cable until down

(fullout) limit switch (Ref.
A. Winch Cable Replacement Figure 202) activates (opens) and
allows brake to engage, thus stopping
(Ref. Replacement of the winch cable (Ref. cable payout.
Figure 202) is required if cable is damaged, NOTE: Three turns of cable will remain on
worn excessively, or cable cutter has been fired winch drum when down limit switch opens.
(Ref. Hoist Equipment Inspection for inspec-
tion requirements and for cable replacement (d). Remove winch cable drum cover.
criteria). (e). Manually raise roller wheel, at top
right rear of winch drum, to close the
(1). Install hoist and support on helicopter down limit switch (release brake) and
(Ref. Hoist Assembly Installation). allow remaining cable to be reeled off
cable drum.
When electrical power is pres- (f). Using control pendant, finish un-
CAUTION ent, make certain cable cutter winding cable. Stop winch when
electrical circuits remain deenergized to cable is fully unwound from drum.
eliminate the possibility of inadvertent ac-
tuation of cable cutter. To avoid possibility of (5). Remove winch cable from drum as
cutting cable, install jumper wire between follows:
cable cutter electrical terminals. (a). Loosen Allen head setscrew securing
cable end in drum anchor hole.
NOTE: An external power source should be Remove cable end from winch by
connected to the helicopter to prevent exces- pulling cable down through cable
sive battery discharge. Hoist uses up to 40 guide, cable cutter, and bumper
amperes electrical current during operation. guide.
Anchor hole setscrew should be
(2). Connect external electrical power CAUTION temporarily tightened to pre-
source to helicopter. vent fouling winch mechanism if winch is
inadvertently operated.
(3). Place BATTERY switch in EXT posi-
(b). Retighten setscrew in anchor hole.
tion.
(6). Remove swivel hook from cable (Ref.
(4). Using hoist pendant control (Ref. Swivel Hook Replacement).
Figure 201), reel off all cable from NOTE: Replacement cable must be 0.125 inch
winch drum as follows: (3.175 mm) diameter stainless steel, 19 by 7
cable strand, extra strength, antispin cable
NOTE: Two persons can facilitate cable remov- with a minimum breaking strength of 1800
al; one person to operate winch and a second pounds. Make certain any replacement
person to handle and coil cable. cable, other than cable supplied by winch
manufacturer, is approximately 113 feet
(a). Operate winch and start reeling cable (34.442 M) long, is equipped with a swaged
off winch drum. ball fitting, and is prooftested to a mini-
mum load of 1850 pounds (840 kg).
To prevent bellmouth wear,
CAUTION cable should not be pulled
(7). Install swivel hook on replacement
cable (Ref. Swivel Hook Replacement).
against side of bellmouth on cable guide.
(8). Attach new replacement cable to winch
(b). As cable unwinds, maintain straight as follows:
downward tension, approximately 15 (a). Insert free end of replacement cable
pounds (6.8 kg); lay or coil cable in a up through bumper pad guide center,
clean clear area. Position cable so bellmouth, switch, cable cutter, and
that cable will not kink or tangle, to between cable rollers in the cable
facilitate rewinding. guide assembly (Ref. Figure 202).
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MAINTENANCE MANUAL
(b). Ensure cable guide assembly is NOTE: The up limit switch should actuate be-
centered and aligned with first fore excessive cable pressure is applied to
groove on double helical screw shaft. vertically compress bumper pad. Permanent
Facing cable guide mechanism, check damage can result if rubber bumper pad is
that guide will travel from right to stowed in a compressed state over an ex-
left when winding cable on drum. tended period of time; rubber bumper will
remain in a compressed (set) state.
(c). Secure cable to drum by loosening set (d). Install cover on winch.
screw and inserting cable end into
(10). Perform an operational check of hoist
drum cable anchor hole until cable system (Ref. Hoist System Operational
end bottoms, approximately 3/8 inch Check).
(9.525 mm); tighten setscrew.
B. Swivel Hook Replacement
(d). Check that replacement cable is (Ref. Figure 202)
positioned in first drum groove at
right when facing cable guide mecha-
nism. Consumable Materials
Item Nomenclature
(9). Operate hoist and wind replacement CM114 Petrolatum
cable on winch as follows:
(1). Remove swivel hook assembly from
(a). Deactivate down limit switch by cable as follows:
manually raising teflon roller wheel
at top right rear of winch drum; use (a). Remove rubber bumper covering
swivel hook housing by pulling
control pendant to wind replacement
bumper upward off top of hook
cable on winch. Release the down housing.
limit switch after three turns of cable
are on drum. (b). Remove cable swaged ball end fitting
from hook housing socket: pull cable
swaged ball fitting through rubber
(b). Maintain sufficient tension, approxi- bumper.
mately 15 pounds (6.8 kg) on cable
while winding cable on drum; check (2). Install swivel hook on cable as follows:
that cable winds straight, smooth,
and snug, without kinking against (a). Lubricate cable swaged ball end
cable windings on drum. Avoid cable fitting with petrolatum (CM114).
rubbing on side of bellmouth during
cable winding. (b). Insert cable through top of rubber
bumper.
(c). Insert cable ball fitting in hook

(c). Continue winding operation until
housing keyway and socket.
entire cable is wound on drum: check
that winch stops automatically when Ensure hook rubber bumper
top of swivel hook pushes against CAUTION completely covers hook housing.
winch rubber bumper pad. (Bumper
pad upward movement actuates (d). Secure cable ball fitting in housing
(opens) fullin (up) limit switch at socket by sliding rubber bumper
cable guide base. down over hook housing.
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MAINTENANCE MANUAL
NOTE: Hook rubber bumper should completely Setscrew mates with indent on cable
cover housing, and bumper base will overlap cutter.
inward around housing base by approxi-
mately 1/16 inch when fully seated on hous- (6). Connect one electrical terminal lug to
ing. cable cutter terminal, leaving protective
shortcircuiting jumper installed on
C. Cable Cutter Replacement cable cutter. Then connect second wire
(GuillotineType) to remaining cable cutter terminal in
the same way.
(Ref. Figure 202)
Protective jumper wire should
CAUTION remain connected to cable cutter
electrical terminals until hoist is to be used.
Item Nomenclature (7). Cover exposed electrical terminal areas
CM425 Sealing compound with sealing compound (CM425).
7. Hoist System Operational Check
Cable must be removed from winch (Ref.
Winch Cable Replacement) before guillotine The following procedure is used to verify the
type cable cutter can be replaced. Replace a capability of the hoist system to function
spent cable cutter guillotine on winch as correctly. The procedure should be performed
follows: any time a malfunction is suspected, and prior
to normal use after repair.
The cable cutter contains an
WARNING explosive squib that is elec- Remove protective electri-
WARNING cal jumper wire (Ref.
trically fired. A protective shortcir-
cuiting electrical jumper should re- Figure 202) from cable cutter whenev-
main connected to cable cutter, not er winch is installed on helicopter.
installed on the winch, to eliminate Jumper wire will prevent operation of
possibility of inadvertent accidental cable cutter in an inflight emergency.
firing. (1). Open applicable passenger/cargo door;
(1). Disconnect two electrical wire terminal extend door retainer tube to hold door
lugs from spent cable cutter. in full open position.
Avoid inadvertent operation of
(2). Loosen two Allen head setscrews at side CAUTION cable cutter. Make certain cable
of movable cable guide and remove
cutter switches are not actuated when hoist
spent cable cutter from guide.
system circuits are energized.
(3). Check that all electrical power is OFF.
(2). Energize helicopter electrical system;
Do not use an ohmmeter or check that both HOIST PWR (power)
WARNING any other device containing and CBL CTR (cable cutter) circuit
an internal voltage source which could breakers are in closed position (Ref.
fire cable cutter. Figure 201).
(4). Using a voltmeter, check for zero (3). Using hoist system control pendant,
voltage between electrical wiring exercise hoist winch by paying out 3 to
terminal lugs; also check for zero 4 feet (1.2 M) of cable under approxi-
current between lugs with a milliamme- mately 15 pounds (6.8 kg) tension; pull
ter. cable straight down to avoid cable
rubbing on cable bellmouth. Reverse
(5). Insert cylindrical end of new cable control and reel cable in. Check that
cutter into winch movable cable guide, cable winds on winch drum evenly and
with shorting jumper positioned that winch operation is smooth and
downward, and secure cable cutter to consistent. Check that winch stops
guide with two Allen head setscrews. automatically when top of swivel hook
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Revision 23 256300
MAINTENANCE MANUAL
rubber bumper pushes against winch (6). Stow door retainer tube; close passen-
bumper pad. ger/cargo door.
(4). Test hoist lifting capability with 300 8. Hoist Equipment Inspection
pound weight. Check that hoist oper-
ates smoothly throughout hoisting and General inspection procedure for the hoist
lowering operations. system is as follows:
NOTE: Cable retraction rate should be approxi- (1). Inspect components for security of
mately 5560 feet (16.818.3 M) per minute. attachment, damage, deformation,
The full usable cable length should unwind cracks, and excessive wear.
in approximately 95 seconds and rewind in
approximately 103 seconds.
WARNING
(a). With helicopter hovering approxi-
mately 100 feet (45.4 M) above test D Human life might depend on cable
weight, lower hoist hook between condition. Inspect full length of cable
fuselage and landing gear skid. carefully and thoroughly.
Continue lowering hook until hook D Use heavy leather gloves to protect
can be connected to test weight. hands from injury due to broken
cable strands.
(b). Gradually maneuver helicopter to
remove cable slack and to center Keep cable clean. Provide a
hoist over test weight. CAUTION clean area to coil cable during
inspection. Dirt and oil grime will create an
(c). Slowly elevate helicopter to raise test
abrasive wear on cable and winch compo-
weight approximately 20 feet (6.1 M)
nents.
from ground.
(d). Using pendant control, payout full (2). Inspect cable for fraying, corrosion,
usable length of cable. Check that broken strands, and security of attach-
hoist down limit switch stops winch ment to winch drum and cable ball
with three turns of cable on winch swivel hook attachment. General
drum. If required, adjust position at criteria for cable replacement are as
which down limit switch activates. follows:
(e). Reverse pendant control. Lift test (a). Any single broken strand (cluster of 7
weight to within approximately 10 individual wires) requires cable
feet (3.0 M) of helicopter skid. replacement.
(f). Lower helicopter and remove hoist (b). Both ends of individual broken wires
hook from test weight; raise hoist should be tucked into cable to
hook and check that hoist winch prevent fouling when cable travels
automatically stops when top of through cable guides and nonfouling
swivel hook rubber bumper pushes mechanisms. Breaks of individual
up against hoist bumper pad. wires are allowable, unless the
number is excessive as defined in
NOTE: Up limit switch should actuate before next criterion.
excessive cable pressure is applied to verti-
cally compress bumper pad (Ref. (c). Generally, one individual broken wire
Figure 202). (two ends) for each foot of cable is
permissible, up to a total of 20
(g). Land helicopter; deenergize electrical individual wire breaks for each 100
system. foot (30.5 M) length of cable. A
greater number of breaks requires
(5). Stow pendant control. cable replacement.
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MAINTENANCE MANUAL
Table 201. Troubleshooting Hoist System
Winch will not raise or lower cable. Tripped circuit breaker. Reset circuit breaker.
Defective pendant control. Repair pendant control.
Defective winch assembly. Repair winch assembly.
Improper lower cable travel limit. Down (fullout) limit switch out of Reset lower limit adjustment.
adjustment.
W3 BUS
A526A12 C
1
2 A527G12N G
3 E19 A527H20N A P107C148S
RECEPTACLE
4 A527J20N B (MATES WITH
5 CYCLIC STICK PT06P148P
6 CABLE CUTTER WINCH PLUG)
CB600 TB10 SWITCH S600 (NOTE 4)
7 P506AH12 1 2
40A M535A12 1
JUMPER E5
AWG 20 CB601 TB116 P130
1 2
M503B20 A M503F20 F 1320
7.5A
B C 1420
SPARE H
D
D
C M504H20
CC8A20 E
CC9A20 F
E24
PENDENT CONTROL
CC10A20
XJ2
CC2AA20 UP
A HOIST
CC1AA20
B
NOTES: DOWN
1. THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING D
CUTTER
DIAGRAMS IN CHAP. 96 FOR COMPLETE CIRCUIT IDENTIFICATION.
C
2. DASHED LINE ( ) ITEMS ARE PART OF HELICOPTER BASIC
MS3101E16S1S
ELECTRICAL SYSTEM. RECEPTACLE
3. COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AND MAY
NOT BE SHOWN ON COMPONENT.
4. REFER TO WINCH SCHEMATIC DIAGRAM FOR INTERNAL CONNECTIONS. G256009
Figure 204. Wiring Diagram Hoist System (L/H Command)
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Revision 23 256300
MAINTENANCE MANUAL
CB600 J28
1 2
A526A12 A526A12 C
40A
SPLICING PERMISSIBLE
HOIST (PWR) OR (ORD) A527G12N G
CB133 A527H20N A
1 2 A527J20N B PT07C148S
40A A526A12
RECEPTACLE
(MATES WITH
HOIST CUT (CTR) CYCLIC STICK PT06P148P
CB134 CABLE CUTTER WINCH PLUG)
1 2 SWITCH S600 (NOTE 4)
M503A20
7.5A
SLAE ONLY
E9
CB601 P616 TB140 TB119 P109
1 2
M503A20 F M503AA20 A M504K20 B M521F20 D
7.5A (NOTE 5) NOTE 6
B A M520F20 E
D K504M20
H SPARE
E24
CC10A20 D
CC8A20 E
CC9A20 F
CABLE CUTTER
0.040 IN. (1.016 MM)
SWITCH BUTTON PENDANT CONTROL
369H9007067 DECAL GRIP
UP
A HOIST
CABLE CUTTER SWITCH DOWN
B
GRIP
CC2AA20 D
CUTTER
CC1AA20 C
CYCLIC GRIP REWORK
MS3101E16S1S
RECEPTACLE
NOTES:
1. THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING DIAGRAM
IN CHAP. 96 FOR COMPLETE CIRCUIT IDENTIFICATION.
2. DASHED LINE ( ) ITEMS ARE PART OF HELICOPTER BASIC ELECTRICAL
SYSTEM.
3. COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AND MAY NOT BE
SHOWN ON COMPONENT.
4. REFER TO WINCH DIAGRAM FOR INTERNAL CONNECTIONS.
5. EXISTING WIRE, RELOCATED TO TB140A.
6. REMOVE EXISTING WIRE M520B20. G256004A
Figure 205. Wiring Diagram Hoist System (R/H Command)
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MAINTENANCE MANUAL
P28 FULLIN
(NOTE) LIMIT SWITCHES
F AWG 20 ORG OR WHT/ORG BRAKE
UP DOWN
G AWG 12 WHT
C AWG 12 RED OR WHT/RED

DOWN UP
MOTOR
FULLOUT
LIMIT SWITCH
E AWG 20 YEL OR WHT/YEL

CABLE CUTTER
SAFETY JUMPER WIRE
(REF. WARNING)
+
AWG 20 GREEN OR WHT/GRN OR BLK
AWG 20 BLU OR WHT/BLU OR WHT

B
NOTE: REFER TO HOIST SYSTEM INTERCONNECT WIRING

DIAGRAMS (REF CHAP. 96) FOR EXTERNAL CONNECTION.
WARNING: REMOVE JUMPER WIRE AFTER INSTALLATION
OR MAINTENANCE (REF. TEXT). G256005
Figure 206. Schematic Diagram Hoist System Winch
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Revision 23 256300
MAINTENANCE MANUAL
HOIST PASSENGER/CARGO
1. Hoist Passenger/Cargo Initial Installation (2). Remove left and right foot support
fairings in passenger/cargo compart-
The passenger/cargo hoist can be installed on ment.
any L/H command or R/H command Model
369D helicopter. On L/H command, the hoist (3). Remove passenger/cargo compartment
winch is installed on the right side of the forward bulkhead trim panel (L/H
fuselage. On R/H command, the hoist winch is command) and controls access door.
installed on the left side of the fuselage. (4). Remove fuel cell forward vent from
Subsequent procedures provide separate control tunnel (Ref. Sec. 280000).
instructions for electrical installations in L/H
command and R/H command to accommodate NOTE: Fuel vent must be removed to avoid
differences in component location and wire damage during structural modification hole
routing. drilling operations.
Installation instructions include procedures for (5). Remove crew compartment seat and
installing a passenger/cargo door retainer back cushions.
assembly, a door sill antichafing bar assembly, (6). Remove left (outboard) collective stick
a winch and winch support tube assembly, and cover.
the electrical wiring and components required
for operation of the hoist system. (7). Remove crew compartment lower aft
trim panels (left and right).
The hoist passenger/cargo installations may be
performed at the discretion of the operator, or (8). Remove crew compartment left or right
the helicopter may be returned to the factory bulkhead panel and lower portion of
for modification. The instructions which follow right upper side panel.
are for the 369H90070521 and 522 installa- (9). Remove edgelighted panel face from
tions only. lower switch and circuit breaker panel
(Ref. Chap. 96). Loosen lower switch
A. Preparation for Installation and circuit breaker panel to accommo-
date installation of additional circuit
Instructions in the following paragraphs are
breakers.
applicable to both left and right hoist installa-
tions, except as noted. C. Helicopter Modification
(1). Identify all components that are to be (Ref. Figure 901) Modification of the helicopter
installed, along with those removed to involves cutting a hole in the fuselage skin to
gain access to work areas. Protect facilitate installation of an electrical receptacle
components from damage and contami- (J28) to receive a winch electrical plug, and a
nation. hole in the lower left area of the canted
bulkhead and forward bulkhead trim panel to
(2). Check that all electrical switches are in facilitate installation of an electrical receptacle
OFF position. (XJ2) to receive a control pendant plug.
Ensure BATTERY switch is in
CAUTION OFF position. Consumable Materials
B. Helicopter Equipment Removal Item Nomenclature
CM318 Primer
Remove following panels, access doors, and
equipment as applicable to accommodate
installation of the hoist system components: (1). Cut and deburr holes, remove chips,
and apply a thin coat of primer
(1). Remove battery (Ref. Chap. 96). (CM318) to exposed metal surfaces.
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256300 Revision 23
MAINTENANCE MANUAL
(2). Fit forward bulkhead trim panel to (Ref. Figure 201) and receptacle nut
canted bulkhead; locate and cut hole in externally to retain J28 receptacle in
trim panel to match XJ2 receptacle hole place.
in bulkhead. Remove trim panel to
accommodate installation of door NOTE: The J28 receptacle is temporarily in-
retainer assembly. stalled to provide a means of determining
wire length to receptacle.
NOTE: Hoist electrical connector (J28) doubler
is located in the crew compartment, below (3). Install circuit breakers in positions
the aft lower corner of the upper canopy CB60l and CB600 respectively, on lower
windshield, and immediately forward of the switch and circuit breaker panel (Ref.
canted frame (Sta. 78.50) for either right View A).
side (L/H command) or left side (R/H com-
mand) hoist winch installation.
(4). (Ref. Figure 204) Install terminal on
circuit breaker jumper wire; install
D. Electrical Equipment Installation (L/H jumper wire on contact 1 of CB60l.
Command)
(5). Install terminal on wire P506AH12 and
Install hoist kit electrical wire harness install on contact 1 of CB600 together
assembly, general wiring, and components on with jumper wire fabricated in previous
L/H command as follows: step. Route wire P506AH12 to contact 7
of BUSS W3; cut wire to length and
Consumable Materials install terminal. Connect wire
(Ref. Section 910000) P506AH12 to contact 7 of BUSS W3.
Item Nomenclature
(6). Install terminal on wire M535A12 and
CM614 Sleeving, heatshrink
connect wire to contact 1 of TB10.
CM703 Tie strap Route wire M535A12 to contact 2 of
CM807 Twine, nylon CB600 and install terminal. Connect
CM815 Solder wire M535A12 to contact 2 of CB600.
(7). Install terminal on wire M503B20 and

Ensure wires and/or wire connect to contact 2 of CB601. Route
CAUTION bundles do not chafe or bind opposite end of wire M503B20 to
control mechanisms. TB116, install pin and insert pin in
TB116, contact A.
NOTE: When providing ground contact for elec-
trical components, clean the contacting sur- (8). Connect terminal of wire A526A12 to
faces to bare metal (Ref. Chap. 96). Route TB10, contact 1, and route wire below
wire and wire bundles with existing wires floor through center beam, below crew
and bundles. Temporarily tie wires in place compartment right seat and up right
with existing bundles until installation is side aft of door frame to J28 receptacle.
complete, then secure wires with nylon
twine (CM807), tiestraps (CM703), or NOTE: Temporarily tie wires in place. Do not
clamps as required. cut wires until all wires are adjusted and
tied in place.
(1). Install cyclic stick grip (Ref. Figure 201
and Sec. 671020). (9). Insert pin of wire CC10A20 in TB116,
contact C. Connect terminal on shield-
(2). From inside crew compartment, ing of wire CC10A20 to ground stud
temporarily install J28 receptacle E24. Do not tighten ground stud nut.
through hole provided in right side of Route wire CC10A20 to J28 receptacle
ship (Ref. Figure 901). Install washer and tie in place.
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MAINTENANCE MANUAL
CUT HOLE IN SKIN TO

MATCH HOLE IN DOUBLER
HOIST ELECTRICAL CON-

NECTOR DOUBLER
UPPER CANOPY
WINDSHIELD
E19
CREW COMPARTMENT
RIGHT DOOR FRAME NOTE: LH COMMAND VERSION SHOWN. RH
COMMAND VERSION IS INSTALLED AT SAME
LOCATION OR LEFT SIDE OF HELICOPTER.
LH COMMAND HELICOPTER
CONFIGURATION, CUT
1.00 IN. (2.54 CM) HOLE IN SKIN WINCH ELECTRICAL RECEPTACLE
(J28) CUTOUT LOCATION
(NOTE)
WL 21.50
2.00 IN.
XJ2 (5.08 CM)
0.970 IN.
(24.638 MM)
(TYP)
2.00 IN.
(5.08 CM)
2.00 IN.
(5.08 CM)
1.50 IN.
XJ2 (3.81 CM)
0.970 IN.
(24.638 MM)
(TYP)
RH COMMAND HELICOPTER CON-
FIGURATION, CUT
VIEW LOOKING FORWARD, LOWER LEFT 1.00 IN. (2.54 CM) HOLE IN SKIN
CORNER OF CANTED BULKHEAD STA. 78.50
0.1210.135 IN.
PENDANT CONTROL ELECTRICAL
(3.07343.429 MM)
RECEPTACLE CUTOUT LOCATION G256006A
HOLE (4 PLCS)
Figure 901. Helicopter Modification
Page 903
256300 Revision 23
MAINTENANCE MANUAL
(10). Install XJ2 receptacle. connect wires A526A12, A527G12N,

A527H20N, A527J20N, CCl0A20,
(a). Insert XJ2 receptacle (Ref. CC8A20, and CC9A20 to J28 receptacle
Figure 201) in hole provided in lower contacts as indicated (Ref. Figure 203).
left corner of canted bulkhead (Ref.
Figure 901). Using XJ2 receptacle (15). Install J28 receptacle and secure with
bracket as a template, mark and drill washer and nut. Install protective cap
four 0.1210.133 inch (3.07343.3782 (Ref. Figure 201).
mm) attach holes. Protect attached
wires during drilling operation. (16). Install ground stud on forward side of
canted bulkhead frame (Ref.
(b). Install XJ2 receptacle (Ref. Figure 901). Identify ground stud as
Figure 201) from forward side of E19.
canted bulkhead, with screws,
washers, and nuts. (17). Install wires A527G12N, A527H20N,
and A527J20N, from J28 receptacle, on
(11). Route wires CC1AA20 and CC2AA20 ground stud E19. Adjust and trim
(Ref. Figure 203) from XJ2 receptacle to insulation tubing (CM614) to accommo-
TB116; install pin of wire CC1AA20 in date ground wire connection as re-
contact B and pin of wire CC2AA20 in quired; heat shrink tubing.
contact D. Connect terminal on shield-
ing of wire CC2AA20 to ground stud (18). Replace existing cyclic stick grip with
E24; tighten ground stud nut. part number 369H90129505 (Ref. Sec.
671020). Wire cyclic stick cable cutter
(12). Route wires CC8A20 and CC9A20 to switch S600 as shown (Ref. Figure 204).
J28 receptacle and tie in place.
E. Electrical Equipment Installation (R/H
(13). Wire J28 receptacle. Command)
(a). Cut and strip wires at J28 receptacle. Install hoist kit electrical wire harness
Ensure sufficient wire length to assembly, general wiring, and components on
provide a smooth right angle wire R/H command helicopters, as follows:
flow to J28 receptacle.
(b). Install approximately 6 inches (15.24
cm) of 0.50 inch (12.7 mm) insulation
Item Nomenclature
tubing (CM614) on wire bundle to
cover all wires extending from J28 CM614 Sleeving, heatshrink
receptacle. CM703 Tie strap
CM725 Tape, electrical, plastic
(c). Ensure that all electrical contact
installations are correct and secure. CM807 Twine, nylon
CM815 Solder
(d). Adjust wires at J28 receptacle and
make certain sufficient wire slack
remains to avoid stress on terminals Ensure wires and/or wire
CAUTION bundles do not chafe or bind
and contacts below floor and seat
areas. Use twine (CM807) and control mechanisms.
tiestraps (CM703) to secure wires in NOTE: When providing ground contact for elec-
place. trical components, clean the contacting sur-
Ensure wires do not chafe or faces to bare metal (Ref. Chap. 96). Route
CAUTION bind throughout full travel of wire and wire bundles with existing wires
any control mechanism. and bundles. Temporarily tie wires in place
with existing bundles until installation is
(14). Remove J28 receptacle from side of complete, then secure wires with nylon
ship. Install insulation sleeving twine (CM807), tiestraps (CM703), or
(CM614) and, using solder (CM815), clamps as required.
Page 904
Revision 23 256300
MAINTENANCE MANUAL
(1). From inside crew compartment, Install pin and insert pin in contact A of
temporarily install J28 electrical TB140.
receptacle (Ref. Figure 201) through
hole provided in left side of ship (Ref. (8). Remove existing wire M520B20 from
Figure 901). Install washer (Ref. TB119A. Wire end is left open insu-
Figure 201) and receptacle nut exter- lated with tape (CM725), and secured to
nally to retain J28 receptacle in place. basic electrical system tiestrap
(CM703). Install pin on wire K504M20
NOTE: The J28 receptacle is temporarily in- and insert in contact A of TB119.
stalled to provide a means of determining Route wire K504M20 to TB140, install
proper length of wires to be connected to re- pin, and insert pin in contact C of
ceptacle. TB140.
(2). On standard R/H command equipped (9). Insert pin of wire CC10A20 in contact C
with 369H92143 circuit breaker panel, of TB140, route wire to J28 receptacle,
install circuit breaker CB600 (Ref. View and temporarily tie in place. Connect
B), and a circuit breaker CB601 in terminal on shielding of wire CC10A20
circuit breaker panel located on the to ground stud E24. Do not tighten
pilots collective pitch stick cover. Make ground stud nut.
certain circuit breaker connections to (10). Install XJ2 receptacle.
buss bar are secure.
(a). Insert XJ2 receptacle in hole pro-
(3). On SLAEequipped R/H command with vided in lower left corner of canted
369D294566 circuit breaker panel, bulkhead (Ref. Figure 901). Using
install circuit breaker CB133 and XJ2 receptacle bracket as a template,
circuit breaker CB134 in circuit breaker mark and drill four 0.1210.133 inch
panel located on the pilots collective (3.07343.3782 mm) attach holes.
pitch stick cover. Make certain circuit
breaker connections to buss bar are (b). Install XJ2 receptacle (Ref.
secure. Figure 201) from forward side of
canted bulkhead, using screws,
(4). (Ref. Figure 205) Install terminal on washers, and nuts.
wire A526A12 and connect to contact 2
of CB600 on standard R/H command, or (11). Route wires CC1AA20 and CC2AA20
to contact 2 of CB133 on SLAE (Ref. Figure 205) from XJ2 receptacle to
equipped R/H command. Route opposite TB140, install pin of wire CC1AA20 in
end of wire A526A12 with existing wire contact B, and pin of wire CC2AA20 in
bundles to J28 receptacle and tempo- contact D. Contact terminal on shield-
rarily tie in place. ing of wire CC2AA20 to ground stud
E24; tighten ground stud nut.
(5). On standard R/H command, locate
existing wire M503A20, install terminal (12). Route wires CC8A20 and CC9A20 to
on wire M503A20, and connect to J28 receptacle and temporarily tie in
contact 2 of CB601. Locate existing wire place.
M503AA20, remove from TB16 contact (13). Wire J28 receptacle.
A, and relocate to TB140, contact A.
(a). Cut and strip wires at J28 receptacle.
(6). On SLAEequipped R/H command, Ensure sufficient wire length to form
install pin on wire M503A20, insert pin a smooth right angle wire flow to J28
in contact A of TB140. Route wire receptacle.
M503A20 to CB134; install terminal
and connect to contact 2 of CB134. (b). Install approximately 6 inches (15.24
cm) of 0.50 inch (12.7 mm) insulation
(7). Install pin on wire M504K20, insert in tubing (CM614) on wire bundle to
contact B of TB119, and route opposite cover all wires extending from J28
end of wire M504K20 to TB140. receptacle.
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256300 Revision 23
MAINTENANCE MANUAL
(c). Ensure that all hoist system electri- F. Passenger/Cargo Door Retainer
cal installations are correct and Installation
secure.
The passenger/cargo door retainer installation
(d). Adjust wires at J28 receptacle and consists of a tubular assembly attached to the
make certain sufficient wire slack aft side of Sta. 78.50 canted bulkhead with
remains to avoid stress on terminals four clamps. With the passenger/cargo doors in
and contacts below floor seat areas. the open position, a telescoping tube slides out
Use twine (CM807) and tie straps of the tubular assembly to engage a bracket
(CM703) to secure wires in place. attached to the door frame, and thus retains
the door in an open position. Install the
Ensure wires do not chafe or
CAUTION bind throughout full travel of
passenger/cargo door retainer as follows:
any control mechanism. (1). Install doubler angles.
(14). Remove J28 receptacle from side of (a). Locate doubler angles (Ref.
ship. Install insulation sleeving Figure 203) on forward side of Sta.
(CM614) and, using solder (CM815), 78.50 canted bulkhead, using two
connect wires A526A12, A527G12N, existing 0.070 inch (1.778 mm)
A527H20N, A527J20N, CC10A20, tooling holes (Ref. Figure 902). Use
CC8A20, CC9A20 to J28 receptacle angles (Ref. Figure 203) as templates
contacts as indicated (Ref. Figure 205). and determine rivet hole locations on
(15). Install J28 receptacle and secure with Sta. 78.50 bulkhead.
washer (Ref. Figure 201) and nut.
Install protective cap. (b). Drill rivet attach holes, 0.0690.074
inch (1.75261.8796 mm).
(16). Install ground stud on forward side of
canted bulkhead frame (Ref. (c). Attach angles to Sta. 78.50 bulkhead
Figure 901). Identify stud as E19. using rivets.
(17). Install wires A527G12N, A527H20N, (2). Install structural reinforcement

and A527J20N from J28 receptacle on brackets.
ground stud E19. Adjust and trim
insulation tubing (CM614) to accommo- (a). Position structural reinforcement
date ground wire connection as re- brackets on forward side of Sta. 78.50
quired; heat shrink tubing. canted bulkhead as shown (Ref.
Figure 902). Locate nine existing
(18). (Ref. Figure 205) Check switch rivets which must be removed prior
MS250894AR (S600) on cyclic stick to installation of reinforcement
grip to verify that button is flush with brackets. Remove rivets using drill
guard. If it is not, the switch must be motor and appropriate drill bit.
reworked, as follows:
(b). Use brackets as templates and
(a). Remove switch from grip (unsolder determine rivet hole locations on Sta.
wiring). 78.50 bulkhead. Drill rivet attach
holes, 0.0690.074 inch
(b). Grind off end of switch button as (1.75261.8796 mm).
shown.
Do not allow file chips to get into (c). Attach brackets to Sta. 78.50 canted
CAUTION switch base. bulkhead using rivets.
(c). Install modified switch in grip and (3). Drill eight 0.1900.199 inch
resolder wiring as shown. (4.8265.0546 mm) holes through Sta.
78.50 canted bulkhead and structural
(d). Install decal 369H9007067 to grip reinforcement angles and brackets at
as shown. locations shown (Ref. Figure 902).
Page 906
Revision 23 256300
MAINTENANCE MANUAL
BL
6.50
CANTED BULKHEAD
(STA. 78.50)
EXISTING
TOOLING BL
HOLES 9.375 IN. 22.60
(23.8125 CM)
DOUBLER 11.44 IN.

ANGLE (29.0576 CM)
WL 34.36
REMOVE EXISTING
RIVETS (9 PLCS)
REINFORCEMENT
STRUCTURAL REINFORCEMENT LOCATION BRACKET
WL 21.50
PASSENGER/CARGO 0.1900.199 IN.

REINFORCEMENT DOOR RETAINER TUBE
BRACKET (4.8265.0546 MM)
HOLE (8 PLCS)
WL 34.36
DOUBLER
BL ANGLE
22.60 PASSENGER/CARGO DOOR RETAINER
TUBE ALIGNMENT AND ATTACHMENT BL
(VIEW LOOKING FORWARD LEFT SIDE) 6.50
G256007A
Figure 902. Passenger/Cargo Door Retainer Tube Installation
Page 907
256300 Revision 23
MAINTENANCE MANUAL
NOTE: Drill retainer tube outboard clamp (1). Remove nylon screws installed in
holes first; install retainer tube and out- support fitting attachment holes on
board clamps to ensure proper alignment for fuselage.
marking and drilling inboard clamp holes.
(2). Install support tube attachment fittings
(4). Install the retainer assembly (Ref. (Ref. Figure 201) on fuselage using
Figure 203) on Sta. 78.50 canted screws and washers.
bulkhead, using clamps, washers, (3). Attach winch to support tube, using
spacers, screws, and nuts. bolts, washers, and nuts. Torque bolts
to 70 100 inchpounds (7.91 11.30
(5). Locate bracket on applicable passenger/ Nm).
cargo door in such a manner as to allow
tube to engage bracket when door is in (4). Attach link assembly to support tube
open position. Install bracket on using bearing pin, washer, and cotter
passenger/cargo door frame using pin.
rivnuts, washers, and screws. (5). Attach winch support tube to fuselage
fittings, using quickdisconnect pins.
G. Hoist Assembly
NOTE: Install pins in position shown (Ref.
(Ref. Figure 201) The hoist assembly consists Figure 201).
of a winch assembly, pendant control assembly, Ensure all electrical power is
hook, hanger, and two attach brackets. To CAUTION off, eliminating possibility of in-
assemble the hoist, proceed as follows: advertent firing of cable cutter.
NOTE: Pendant assembly is shipped as- (6). Remove protective cap from electrical
sembled with no additional assembly re- receptacle on side of fuselage. Connect
quired. winch electrical plug to fuselage
receptacle. Secure wire harness to
(1). Install hanger on winch, using screws, support tube, using tiestraps (CM703).
lockwashers, and washers. Remove protective electri-
WARNING cal jumper wire (Ref.
(2). Remove existing attach brackets from Figure 202) from cable cutter whenev-
winch. Install replacement brackets on er winch is installed on helicopter.
winch frame, using existing hardware. Jumper wire will prevent operation of
cable cutter in an emergency.
H. Hoist Installation
(7). Install the hoist operators body
The hoist system winch is mounted on a harness (Ref. Figure 201).
support tube and attached with quickrelease
safety pins to three fittings installed on either (8). Install flush rivets in wheel fittings
side and above the passenger/cargo compart- after removing existing rivets from
ment door. The support tube positions the locations shown (Ref. Figure 903).
winch to raise and lower the cable between the NOTE: Do not install rivets if wheel fittings
side of the fuselage and the landing gear skid. have been previously equipped with flush
The winch and support can be installed for use rivets.
on either the left or right side of the helicopter
as applicable. Install the hoist system as (9). Install rivnuts at locations shown (Ref.
follows: Figure 903). Secure clips (Ref.
Figure 201) to fuselage, using screws
and washers. Install bar assembly,
Consumable Materials using screws, washers, and nuts.
(10). On R/H command, install landing gear
Item Nomenclature
skid chafing bar assembly
CM703 Tie strap (369D292556) as follows (Ref.
Figure 903):
Page 908
Revision 23 256300
MAINTENANCE MANUAL
(a). Remove bolts from inboard side of aft (2). Install edgelighted and circuit breaker
abrasion strip (369H6102), and aft panels as applicable (Ref. Chap. 96).
bolt from inboard side of forward
abrasion strip (369H6102), on left (3). Install crew compartment left or right
landing gear skid. bulkhead panel and lower portion of left
or right upper side panel as applicable.
(b). Install screw (NAS6038) in forward
attach hole of aft abrasion strip (4). Install crew compartment lower aft
(369H6102). trim panels (left and right).
(c). Position chafing bar on inboard side (5). Install left (outboard) collective stick
of left skid with bent end of bar aft, cover.
and 3/8 inch (9.525 mm) recess hole
in chafing bar over aft abrasion strip (6). Install seats and back cushions.
forward attach screw.
(d). Align chafing bar aft screwhole with (7). In passenger/cargo compartment,
aft abrasion strip aft attach hole; install fuel cell forward vent in control
install screw (NAS6038) to secure tunnel (Ref. Sec. 280000).
aft portion of chafing bar. (8). In passenger/cargo compartment,
(e). Hold chafing bar against skid; locate install controls access door and foot
bar forward screw hole over forward support fairings.
abrasion strip aft attach hole; drill
0.1900.200 inch (4.8265.08 mm) NOTE: The forward bulkhead, Sta. 78.50, trim
screw hole through chafing bar. panel is not installed during use of the hoist
system door retainer equipment.
(f). Install screw (NAS6038) to secure
forward end of chafing bar. (9). Install battery.
I. Helicopter Equipment Installation (10). Perform operational check of hoist
system (Ref. Hoist System Operational
Install equipment and panels as follows:
Check).
Remove all tools and foreign
CAUTION materials from helicopter before J. Weight and Balance Data
panel installations.
(Ref. After installation of the hoist system,
(1). Prior to closing access areas, check incorporate changes in the helicopter weight
integrity of entire hoist system installa- and balance records as instructed (Ref. Sec.
tion. 081000).
Weight Arm Moment
Configuration
Pounds (kg) inches (cm) inlb (kg cm)
369H90070521
+42.3 (+19.187) +98.0 (+248.92) +4145 (+4775.5)
(R/H Command)
369H90070522
+39.3 (+17.826) +98.7 (+250.70) +3879 (+4469.1)
(L/H Command)
Page 909
256300 Revision 23
MAINTENANCE MANUAL
WHEEL FITTING
LANDING GEAR SKID REMOVE EXISTING RIVETS

(INBOARD SIDE) (2 PLCS), INSTALL FLUSH
RIVETS
CABLE ANTISNAG PROVISIONS

(ROTATED)
AFT ABRASION FORWARD ABRASION

STRIP STRIP
LEFT SKID (IN-

BOARD SIDE)
CHAFING BAR
LEFT LANDING GEAR SKID CHAFING BAR PROVISION

(RH COMMAND HELICOPTERS WITH
CENTER ELECTRICAL CONSOLE ONLY)
STA. STA.
96.92 85.69
1.12 IN. INSTALL RIVETS 1.12 IN.
JACK FITTING
(2.8448 CM) (2 PLCS) (2.8448 CM)
0.47 IN.
(11.938 MM)
16.03 IN. 11.20 IN.

(40.7162 CM) (28.448 CM)
STA.
112.92
DOOR SILL ANTICHAFING BAR PROVISIONS
G256008A
Figure 903. Cable Antichafing Bar Installation
Page 910
Revision 23 256300
MAINTENANCE MANUAL
Chapter
26
Fire Protection
MAINTENANCE MANUAL
TABLE OF CONTENTS
261000 Engine Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Fire Detector System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fire Detector System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fire Detection System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fire Detection System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fire Detection System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Fire Detection System Interconnect Data . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Fire Detection System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
262000 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fire Extinguisher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fire Extinguisher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fire Extinguisher Servicing/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Fire Extinguisher Installation (R/H Command) . . . . . . . . . . . . . . . . . 202
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
261000
Engine Fire
Detection System
MAINTENANCE MANUAL
FIRE DETECTION SYSTEM

1. Fire Detector System Description and 3. Fire Detection System Replacement
Operation
(Ref. Figure 202)
The fire detection system is located in the aft
section of the fuselage encircling the engine A. Fire Detection System Removal
bay area. The fire detector cable is looped
around the inboard structure of the engine (1). Disconnect wire harness from fire
compartment. The fire detection system is held detector unit.
in place by stainless steel positive locking
cable clips and clamps attached to the air- (2). Remove hardware securing clamps from
frame. cable and fire detector unit.
The detector consists of a pressure switch (3). Disconnect fire detection cable quick
connected to a small diameter tube. Inside the release clips.
tube is helium gas and a core material that
contains trapped hydrogen. The detector can (4). Careful remove fire detection cable
provide an output signal when heat is applied from engine compartment.
to it in two ways. If the detector tube average
temperature exceeds a preset amount, the (5). Replace any broken quick release clips.
helium gas pressure increase will trigger the B. Fire Detection System Installation
output signal. If there is a local hot spot on the
detector tube, the core will outgas hydrogen. NOTE:
The release of hydrogen gas will cause a
pressure increase inside the tube, triggering D Replace any damaged or broken quick re-
the output signal. Both of these processes are lease clips.
reversible. When the tube cools, the output D Do not exceed minimum bend radius
signal ceases, the hydrogen is readsorbed into 0.375 inch (9.53 mm) when installing fire
the core, and the system is reset. The detector detection cable.
core has a spiral groove cut into its outside
diameter, so that crushing, flattening, or (1). Form fire detection cable to fit original
kinking of the detector tube will not prevent mounting locations.
gas pressure from reaching the pressure
switch. Loss of tube integrity through cracking (2). Secure fire detector cable in quick
or breakage will make the detector inopera- release clips.
tive, but the detector incorporates a built in
test for tube integrity. (3). Install clamps to fire detector unit
using previously removed hardware.
2. Fire Detector System Troubleshooting
(4). Attach electrical connector to fire
(Ref. Figure 201) detection cable connector.
Page 201
261000 Revision 23
MAINTENANCE MANUAL
J 1201
TB2011 P19 VOICE/WARNING LRU

89 FIR 002AA22 E F G H FIR 002AAA22 S
P/J 30
FIR 002A22 D
78 FIR 001A22 C
B
79 FIR 001F22
A
1 FIR 003A22
FIRE DETECTOR
6G26095A
Figure 201. Fire Detection System Interconnect Data
Page 202
Revision 23 261000
MAINTENANCE MANUAL
FIRE DETECTOR UNIT
VIEW ROTATED
MS21919WCH2 CLAMP
MS21919WCH16 CLAMP
300131900/400
FIRE DETECTOR
MS21919WCH2 CLAMP
NAS1096312 SCREW
MS210423 NUT
NAS43HT320 SPACER MS3456KT14S5S PLUG
AN960C10L WASHER M85049/52S14W BACKSHELL
MS9029/30217 SOCKETS (X5)
LOOKING OUTBOARD
LEFT SIDE
6G26094
Figure 202. Fire Detection System Installation

261000 Revision 23
MAINTENANCE MANUAL
Section
262000
Fire Extinguisher
MAINTENANCE MANUAL
FIRE EXTINGUISHER
1. Fire Extinguisher Description (2). Remove fire extinguisher from mount-
ing bracket.
(Ref. Figure 201) The early model helicopters (3). Remove safety pin from handle. Point
use the pressurized, dry chemical type of fire nozzle toward base of flame and
extinguisher. The current models use a squeeze the handle.
liquified gas which discharges as a vapor at
high nozzle velocity (Halon 1211). The L/H and 3. Fire Extinguisher Servicing/Inspection
R/H command fire extinguishers mount on the
forward door frame between the crew door and The fire extinguishers are equipped with a
the canopy. The fire extinguisher quickly pressure gage that indicates normal, charge,
detaches from the mounting bracket by and overcharge pressures.
unfastening the quickrelease clasps. Note the
current fire extinguishers are equipped with (1). Dry chemical type white area indi-
two straps for extra high vibration applica- cates normal operating range of 150 psi
tions. (1034 kPa). Red area indicates
CHARGE or OVERCHARGE.
2. Fire Extinguisher Operation (2). Halon type green area indicates

normal operating range of 125 psi (862
kPa). Red area indicates CHARGE or
(1). Grasp fire extinguisher handle with one OVERCHARGE.
hand. Use the thumb and forefinger of
the other hand to unfasten the quick Service the fire extinguishers in accordance
release clasp. with manufacturers instructions.
Page 201
262000 Revision 23
MAINTENANCE MANUAL
EARLY ASSEMBLY
CURRENT ASSEMBLY
G262001
Figure 201. Fire Extinguisher Installation (R/H Command)
Page 202
Revision 23 262000
MAINTENANCE MANUAL
Chapter
28
Fuel System
MAINTENANCE MANUAL

MAINTENANCE MANUAL
TABLE OF CONTENTS
280000 Fuel System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Fuel Quantity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Fuel Shutoff Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Start Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8. Fuel Filter Caution Light Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. Drain System and Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10. Fuel Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Fuel System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Fuel Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101. Fuel System Wiring Diagram (Model 250C20B/R2 Engines) . . . . . 103
Figure 102. Fuel Quantity System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 103. Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1. Fuel Cell Cleaning General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Uniroyal Fuel Cell Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Engineered Fabrics Corp. Fuel Cell Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Fuel Cell Handling, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Fuel Cell Preservation and Storage (Uniroyal Cells) . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Fuel Cell Preservation and Storage (Engineered Fabrics Corp. Cells) . . . . . . . . . . . 201
7. Fuel System Air Bleed (Model 250C30 Engine Installation) . . . . . . . . . . . . . . . . . . 202
8. Fuel System Air Bleed (Model 250C20B/R2 Engine Installation) . . . . . . . . . . . . . . 202
1. Fuel Shutoff Valve Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Fuel Shutoff Valve Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Fuel Shutoff Valve Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Fuel Shutoff Valve Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Fuel Shutoff Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Fuel Shutoff Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Fuel Shutoff Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Left Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Page i
MAINTENANCE MANUAL

3. Fuel Tank Vent System Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Vent Tube/Emergency Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Forward Vent Crossover Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
C. Aft Vent Crossover Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. Vent System (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
D. Fuel Tank Vent System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
E. Vent Tube/Emergency Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 408
4. Fuel Supply Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Fuel Supply Lines Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Fuel Supply Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
5. Start Pump Replacement (Model 250C20B/R2 / 250C30 Engine Installation) . 409
A. Start Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Table 401. Fuel Line Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Start Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 404. Start Pump and Fuel Lines Installation (Sheet 1 of 4) . . . . . . . . . . . 411
6. Fuel Quantity Transmitter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Fuel Quantity Transmitter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Fuel Quantity Transmitter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
7. Fuel System Drain Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Fuel System Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Fuel System Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
8. Fuel Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Fuel Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Fuel Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
C. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Figure 405. Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 406. Fuel Cell Support Lacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Fuel Level Low Caution Light System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Fuel Quantity Transmitter Calibration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 1 of 2) . . . . . . . . . . . . 502
A. Fuel Level Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
B. Fuel Level Low Warning Light Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
3. Fuel Quantity Transmitter Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4. Fuel Filter (Bypass) Caution Light Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . 506
Figure 502. Fuel Filter Caution Light Pressure Switch Test
(C20/C30 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
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Figure 503. Fuel Filter Caution Light Pressure Switch (C30 Engine) . . . . . . . . . 509
Figure 504. Fuel Filter Caution Light Pressure Switch (C20 Engines) . . . . . . . . 509
Figure 505. Fuel Filter Caution Light Pressure Switch (C20R/2 Engines
with CECO Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
1. Fuel System General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Fuel Shutoff Valve Control Cable Swage Test (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Fuel ShutOff Control Cable, PN 369A8137503 Pull Test . . . . . . . 602
3. Fuel Shutoff Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Fuel Quantity Transmitter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Tank Vent System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6. Fuel System Vacuum Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
7. Start Pump Operational Check (Model 250C20 Series Engines
or 250C30 Engine With Optional Maintenance Fuel Pump) . . . . . . . . . . . . . . . . . . 605
8. Drain Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
9. Fuel Cell Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
10. Fuel Cell Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
A. Soap Bubble Leak Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
B. Phenolphthalein Stain Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
C. Liquid Stand Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
11. Fuel Tank Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Fuel Shutoff Valve Control Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Fuel Shutoff Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Fuel Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Uniroyal SelfSealing and NonSelfSealing Cell Repairs . . . . . . . . . . . . . . . . . . . . . 801
A. Scuff Mark Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
B. Reinforcements, Hangers and Splice Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
C. Loose Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
D. Patch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
E. Loose Edge and Lap Seam Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
F. Blister Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5. Fuel Quantity Transmitter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Resistor installation, Transmitters PN369D296303, 369D296303701 and
369A4245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. MILS8802 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
280060 Fuel System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2. Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Fuel Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Fuel Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Fuel Quantity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Fuel Shutoff Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8. Fuel Filter Caution Light Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. Drain System and Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10. Fuel Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Fuel System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Fuel Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 102. Fuel Quantity System Wire Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 101. Fuel Quantity System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 103
1. Fuel Cell Cleaning General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engineered Fabrics Corp. Fuel Cell Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fuel Cell Handling, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Fuel Cell Preservation and Storage (Engineered Fabrics Corp. Cells) . . . . . . . . . . . 201
5. Fuel System Air Bleed (Model 250C47 Engine Installation) . . . . . . . . . . . . . . . . . . 201
Figure 201. Field Fabricated Fuel System Bleeding Tool . . . . . . . . . . . . . . . . . . . . 202
1. Fuel Shutoff Valve Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Fuel Shutoff Valve Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Fuel Shutoff Valve Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Fuel Shutoff Valve Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Fuel Shutoff Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Fuel Shutoff Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Fuel Shutoff Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Fuel Shutoff Valve and Fuel Cell Cover Installation . . . . . . . . . . . . . 404
3. Fuel Cell Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Fuel Cell Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4. Fuel Supply Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Fuel Supply Lines Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Fuel Supply Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Fuel Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
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Figure 404. Ejector Pump and Fuel Lines Installation . . . . . . . . . . . . . . . . . . . . . . 409
5. Fuel Cell Vent System Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Fuel Cell Vent System Components Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Fuel Cell Vent System Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 405. Fuel Cell Vent System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
6. Fuel Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Fuel Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Fuel Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Figure 406. Fuel Cell Interconnect and Support Lacing (Sheet 1 of 3) . . . . . . . . 416
7. Fuel Filler Neck Gravity Fill Port Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Fuel Filler Neck Gravity Fill Port Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Fuel Filler Neck Gravity Fill Port Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
8. Fuel System Drain Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Fuel System Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Fuel System Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
9. Fuel Quantity Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Forward Fuel Quantity Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Forward Fuel Quantity Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
C. Aft Fuel Quantity Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 407. Fuel Quantity Probes (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
D. Aft Fuel Quantity Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Fuel Level Low Light/Fuel Quantity Indicator System Test and Calibration . . . . 501
2. Fuel Filter (Bypass) Caution Light Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . 502
Figure 501. Fuel Filter Caution Light Pressure Switch Test Apparatus
(C47 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
1. Fuel System General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Fuel Shutoff Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Tank Vent System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Fuel Quantity Probe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5. Fuel System Vacuum Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601. Fuel System Vacuum Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6. Drain Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
7. Fuel Cell Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
8. Fuel Cell Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
A. Soap Bubble Leak Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
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B. Phenolphthalein Stain Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
C. Liquid Stand Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
9. Fuel Tank Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
10. Fuel Transfer System Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 602. Fuel Transfer System Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 606
A. Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 603. Fuel Transfer Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
B. Check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Fuel Shutoff Valve Control Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Fuel Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Scuff Mark Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Reinforcements, Hangers and Splice Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
5. Loose Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
6. Patch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
7. Loose Edge and Lap Seam Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8. Blister Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
282500 AntiIce / Airframe Fuel Filter (369D/E 500/600N) . . . . . . . . . . . . . . . . . . . . A
Table 1. AntiIce/Airframe Fuel Filter Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. AntiIce Fuel Filter System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. AntiIce Fuel Filter System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . 101
1. AntiIce Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. AntiIce Fuel Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. AntiIce Fuel Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fuel System Air Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. AntiIce Fuel Filter (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1. AntiIce Fuel Filter System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. AntiIce Fuel Filter Installation Operational Check: 369H90022BSC . . . . . . . . . 602
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3. AntiIce Fuel Filter Installation Operational Check: 369H90022503, 505
and 600N98110501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Fuel System Vacuum Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Fuel Supply System Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601. AntiIce Fuel Filter Controls (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 604
1. AntiIce Fuel Filter Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Preparations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. AntiIce Fuel Filter Control Panel Installation: 369H90022BSC . . . . . . . . . . . . 901
C. AntiIce Fuel Filter Control Panel Installation: 369H90022503, and 505 . . . 901
D. AntiIce Fuel Filter Control Panel Installation: 600N98110501 . . . . . . . . . . . . 902
E. Firewall Modifications and Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
F. Fuel Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Figure 901. AntiIce Fuel Filter Modifications and Installation
(369D/E 500N) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902. AntiIce Fuel Filter Modifications and Installation (600N)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. AntiIce Fuel Filter Wiring Diagram (369D S/N 0001 1204)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
Figure 904. AntiIce Fuel Filter Wiring Diagram (369D S/N 1205 & Subs
and 369E S/N 001 383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Figure 905. AntiIce Fuel Filter Wiring Diagram (369E S/N 384 & Subs
and 500N S/N 001 & Subs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
Figure 906. AntiIce Fuel Filter Wiring Diagram (600N S/N 003 & Subs)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 914
G. PostInstallation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
H. Furnishings, Panels and Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
2. AntiIce Fuel Pump Initial Installation (600N98110501 Installation) . . . . . . . . . 916
A. Fuel Cell Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
Figure 907. Fuel Pump Initial Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . 917
B. Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
C. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
3. AntiIce Fuel Filter Installation Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . 918
Page vii
MAINTENANCE MANUAL

Page viii
MAINTENANCE MANUAL
Section
280000
Fuel System
(369D/E/FF 500N)
MAINTENANCE MANUAL

MAINTENANCE MANUAL
FUEL SYSTEM
1. Engine Fuel System (6). Fuel tank servicing is through the tank
filler neck on the right side of the
(1). Engine fuel system operational infor- fuselage.
mation is provided in the applicable
Allison Engine Operation and Mainte- 3. Fuel Quantity System
nance Manuals (Ref. Sec. 010000). (1). The fuel quantity system is powered by
24 28 Vdc current and consists of a
2. Fuel Cells float operated quantity transmitter
mounted on the left fuel cell cover and a
(1). The MDHS helicopter standard fuel quantity indicator gauge and FUEL
tank consists of two interconnected LEVEL LOW caution light on the
nonselfsealing bladder cells having a instrument console. Early series
total capacity of 64 U.S. gallons (242.3 helicopters incorporate the gauge as
L), with 62 gallons (234.7 L) usable. part of a threepack instrument cluster.
Alternate selfsealing cells may be Current helicopters feature an individ-
installed having a capacity of 62 U.S. ual quantity gauge. The system is
gallons (234.7 L), with 60.7 gallons protected by the INSTR CLUSTER 5
(229.7 L) usable. Bladder and self ampere circuit breaker. Power is
sealing fuel cells are supplied by supplied to the system from the DC bus
Engineered Fabrics Corporation and through the INSTR CLUSTER circuit
Uniroyal, Inc. (Ref. Sec. 010000). breaker, CB101. With power on and
approximately 35 or 70 pounds of fuel
(2). Cells are located in separate fiberglass remaining, depending on customer
lined bays below the passenger com- requirements, the fuel quantity trans-
partment floor. Both cells are supported mitter float arm contacts a spring wire
by a system of airframe brackets, that completes a circuit to ground
hangers, grommets and nylon suspen- through a transistor located on a circuit
sion cords. board inside the transmitter assembly.
The transistor switches on the FUEL
(3). Each fuel cell is equipped with an LEVEL LOW caution light. Refueling
access cover fitting, cover, forward and raises the float, breaks the transistor
aft vent crossover fittings, fuel intercon- circuit and switches off the FUEL
nect fittings, internal baffles and baffle LEVEL LOW caution lamp. The float
support rods. operates a rheostat that controls
electrical current through the quantity
(4). The right fuel cell contains the male indicator circuit. Fuel level changes
portion of the cell interconnect fitting, alter transmitter resistance values that
filler neck, cap and attached filler effect the fuel quantity indicator needle
shield. position.
4. Vent System
(5). The left fuel cell contains the female
half of the cell interconnect fitting, (1). Tank cells are vented to atmosphere
sump plate, sump/tank drain valve, through bottom and side fuselage ports
engine start fuel pump (C20 series by a system of interconnected hoses and
engine installation) or fuel inlet fitting tubes attached to the forward and aft
(C30 engine installation). The left cell ends of each fuel cell. A fuel vent
cover supports the fuel quantity emergency shutoff valve automatically
transmitter, manually actuated fuel closes to prevent fuel loss through the
shutoff valve, fuel supply tubes, hoses vent system when a 45 helicopter pitch
and attaching hardware. or roll angle limit is exceeded.
Page 1
280000 Revision 19
MAINTENANCE MANUAL
5. Fuel Shutoff Valve Control filter pressure AF (after filter) and BF

(before filter) ports just upstream of the
(1). A red fuel shutoff control knob labeled engine fuel pump. The switch is
FUEL, PULL TO CLOSE is located on sensitive to a preset differential
the instrument panel face. The flexible pressure. An increase in BF pressure
cable and housing is routed aft under with a concurrent decrease in AF
the floor to the shutoff valve lever on pressure due to partial or complete
the left fuel cell access cover. filter blockage may intermittently or
completely close the switch depending
6. Fuel Shutoff Valve on the nature of the filtered material.
(1). The cable actuated, mechanically Switch contacts complete an electrical
detented fuel shutoff valve is located on circuit through a case ground that
the left fuel cell access cover. Valve switches on the FUEL FILTER
lever arm travel from full open to closed caution lamp, a part of the instrument
is 90. console caution and warning light
array.
7. Start Pump
9. Drain System and Drain Valves
NOTE: Helicopters with C30 engines are not
equipped with a start pump. Fuel is drawn (1). One spring loaded plunger drain valve
from the tank by the enginedriven fuel is installed in the fuel tank sump plate.
pump.
Air in the fuel system will
(1). Helicopters with C20 series engines are WARNING cause a power reduction or
equipped with a submerged, single
flameout. Do a fuel system vacuum leak
stage centrifugal, 24 28 Vdc, 4.5
check and system air bleed after open-
ampere, negative ground, electric start
ing fuel system to atmosphere and
pump bolted to the sump plate in the
prior to releasing helicopter for flight.
left fuel cell. Pump delivery volume at
sea level is 300 lbs/hr (136 kg/hr), NOTE: The tank sump drain valve is installed
nominal at 10 psi (68.95 kPa), mini- in the tank sump mount plate on the bottom
mum. Delivery at 20,000 feet (6100 M) of the left fuel cell. The valve is accessed
is 120 lbs/hr (54.48 kg/hr), nominal at from under the helicopter.
11 psi (75.84 kPa), minimum. The start
pump is controlled by a 7.5 ampere (2). An additional drain valve and asso-
circuit breaker/switch on the instru- ciated tubing is installed on helicopters
ment panel. equipped with an optional antiice
(2). 369F Maintenance Fuel Pump (airframe) fuel filter.
Helicopters with C30 engines are not
equipped with a start pump. An 10. Fuel Supply Lines
optional maintenance fuel pump with
the same specifications as the C20 (1). The engine fuel supply lines consist of:
series engine submerged start pump
can be installed. The maintenance fuel (a). A hose between the start pump (C20
pump is used to bleed or purge fuel engines) or fuel pickup fitting (C30
lines after maintenance and is not used engines) to the fuel shutoff valve.
during engine operation. The mainte-
nance fuel pump is controlled by a 7.5 (b). A tube between the fuel shutoff valve
ampere circuit breaker/switch on the and firewall fitting.
instrument panel.
(c). A hose from the firewall fitting to the
8. Fuel Filter Caution Light Pressure Switch engine filter inlet port.
(1). A differential pressure switch is (d). Associated elbows, fittings and

installed across the engine fuel pump unions.
Page 2
TR10002 280000
MAINTENANCE MANUAL
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Fault Isolation
Table 101. Fuel Supply System Fault Isolation
Start pump supplies Fuel tank empty. Refuel helicopter.

insufficient or no fuel to
engine. Defective start pump. Replace start pump.
Disconnected or ruptured fuel Check all fuel lines for security and condition.
line. Repair or replace parts as required.
Clogged fuel line. Repair as required.
Clogged fuel cell and start Clean as required.

pump inlet screens.
Twisted or kinked fuel supply Repair as required.

hose.
Defective fuel shutoff valve. Repair or replace fuel shutoff valve.
Fuel shutoff valve control Repair or replace control cable.

cable failed or disconnected.
FUEL FILTER warning light Clogged engine fuel filters. Replace pump and gas producer fuel control
on. filters. Clean fuel control pneumatic (air)
circuits (refer to Allison Engine Operation and
Maintenance Manual). When installed, replace
antiice (airframe) filter. Bench check FUEL
FILTER caution light pressure switch.
Fuel contamination Inspect and clean the fuel cell and start pump
inlet screens if large amounts of foreign
material are found in the engine driven fuel
pump filter (or the optional airframe fuel filter if
installed).
Defective fuel filter pressure Replace pressure switch.

switch.
Wiring fault. Repair wiring.
Engine power surge or Water/ice in fuel system. Drain water out of tank and fuel supply system.
flameout with start pump ON
and adequate fuel on board.
Engine power surge or Water/ice in fuel system. Same as above.

flameout with start pump OFF.
Air in fuel system. Bleed fuel system.
Air leaking into system. Vacuum leak check fuel supply system.
Page 101
280000 Revision 29
MAINTENANCE MANUAL

Bottom of fuselage stays wet Loose or broken lines or Inspect and repair as required.
with fuel. fittings.
Fuel tank leak. Remove, test and repair, or replace cells.
FUEL LEVEL LOW caution Transistor current leakage Install resistor in transmitter circuit.
light stays on, glows or flickers through FUEL LEVEL LOW
with known quantity above low caution lamp.
level.
Defective fuel quantity Remove, test, calibrate and repair or replace
transmitter. fuel quantity transmitter.
Erroneous fuel quantity gauge Loose or defective wiring or Inspect wiring and repair.
readings. connections.
Defective gauge. Remove, test and replace a defective gauge.
Defective fuel quantity Remove, test, calibrate and repair or replace

transmitter. transmitter.
NOTE: 369FF Helicopters are not equipped with a start pump.
Page 102
Revision 19 280000
MAINTENANCE MANUAL
P250J
CB118 P9J START PUMP
1 2 START PUMP b A
7.5A
E8 B
B250
TB5039
NOTE A
D NOTE
G NOTE
DIMMER
INDICATOR
P12 LIGHTS
NOTE L
TB6
START PUMP B
TB10 ON LT
SP24 SB23
R1 C 2 1
D GND BUS
NOTE A B B A
330 SW PNL
XDS7 NOTE E33A
NOTE: EFFECTIVE ON 369E 500N HELICOPTERS. G280012A
Figure 101. Fuel System Wiring Diagram (Model 250C20B/R2 Engines)
CB101
1 2
C
5A REF SEC
J FUEL QTY
9800 FUEL QTY SENDER
P9J P251J
B M35 L B BLU
J D RED
DS143
E31 DIMMER E5 E BLK
IND LTS P12
K R251
a
GND BUS
DS11
G280013
Figure 102. Fuel Quantity System Wiring Diagram
Page 103
280000 Revision 19
MAINTENANCE MANUAL
28 VDC BUS
START PNL INSTR

PUMP LTS CLUSTER
CB118 CB104 CB101
S202 RT301
ENG ENG OIL
OIL SEND
IGN TEMP
TEMP SENDER FLOAT
IND
GND
GND
J251P FUEL LEVEL SENDER
FUEL
IGN QTY SEND
B
IND R251
S203 D 1K
H 510
P250 START PUMP
A
B
P12 DIMMER
PRESSTOTEST
SWITCH XDS21
a
C NC
NO
B
START XDS21S2 WARN LT
PUMP +28 VDC FUEL LOW K
ON LT IN FUEL
XDS21S1
NO FILTER
C
NC A
N
b
S303
FUEL
FILTER
SWITCH
NOTES: START PUMP CIRCUITRY NOT

EFFECTIVE ON 369FF HELICOPTERS.
G280014A
Figure 103. Fuel System Schematic
Page 104
Revision 23 280000
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Cell Cleaning General 4. Fuel Cell Handling, Storage and Shipping
Do not use cell fittings as hand
CAUTION holds. Do not store fuel cells un-
(1). Fuel cells are susceptible to fungus
growth after contact with contaminated crated or exposed to direct sunlight, ozone,
fuel. Fungus trapped in the fuel filters dirt, moisture, solvents, chemicals, or ex-
indicates fuel tank contamination. tremes of heat and humidity.
Remove, inspect, clean or replace filter
elements per applicable Allison Engine (1). Store and ship cells in a suitable
Operation and Maintenance Manual. protective container.
Where installed, service antiice (a). Apply protective tape over all cell
(airframe) filter (Ref. Sec. 282500). machined fittings.
(b). Use packing material to keep the cell
(2). Periodic incorporation of an FAA from shifting in transit.
approved antifungal fuel additive will
kill and prevent new fungus growth. (c). Suspended selfsealing cells to
maintain cell shape.
2. Uniroyal Fuel Cell Cleaning 5. Fuel Cell Preservation and Storage

(Uniroyal Cells)
Steam cleaning may cause ir- CAUTION

CAUTION reparable cell damage. Do not
use MEK, soap or commercial cleaning de- D Uniroyal cells removed from service must
tergents to clean rubberized fabric fuel cells. not be left dry for more than 10 days with-
Some cleaning agents leave a residue that out the application of oil as a plasticizing
will react with fuel to form materials that agent. The cell liner will loose pliability if
can block fuel filters. left dry for extended periods and subse-
quent flexing may cause the material to
crack.
(1). Clean Uniroyal fuel cell interior/exter- D Do not work on cell in ambient tempera-
ior surfaces with lint free cloth moist- tures below 50F (10C).
ened with water, alcohol or kerosene.
No other cleaning materials should be (1). Before removing cell from airframe:
used.
(a). Spray or wipe exposed internal and
external cell surfaces with SAE 10
3. Engineered Fabrics Corp. Fuel Cell petroleum based oil.
Cleaning (b). Allow oil to soak into cell for 24 hours
to soften cell material prior to
handling or folding.
Do not steam clean Engineered
CAUTION Fabrics Corp. fuel cells. Steam (c). Mop up puddled oil.
cleaning may cause irreparable damage.
6. Fuel Cell Preservation and Storage
(Engineered Fabrics Corp. Cells)
(1). Clean cell exterior and interior surfaces
with warm soapy water and clean lint NOTE: Engineered Fabrics Corp. VITHANE/R
free cloth. Rinse away all soap residue fuel cells do not require oiling for preserva-
and wipe dry. tion.
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280000 Revision 19
MAINTENANCE MANUAL
(1). Thoroughly clean cell with warm soapy NOTE: Check fuel supply system for leakage
water. Wipe completely dry. with vacuum (Ref. Fuel System Vacuum
Leak Inspection).
Do not work on cell in ambient
CAUTION temperatures below 70F 8. Fuel System Air Bleed (Model
(21C). 250C20B/R2 Engine Installation)
(a). Fold cell over protective wadding as Fuel/air vapor discharged

loosely as possible and with a mini- WARNING during bleeding is a fire haz-
mum number of folds. ard. Prevent fuel vapor accumulation,
ignition and fire. Perform work in an
(b). Wrap the cell in a protective cover. open, well ventilated area away from
all potential ignition sources. Attach
(c). Put cell in a suitable storage/ship- helicopter to an approved electrical
ping container. Use wadding as ground. Wear approved eye protection.
required to prevent movement. Do
not stuff cell into an undersized (1). Bleed air from helicopter fuel systems
container. as follows:
Do not operate start pump in an
(d). Store cell at 70F (21C) away from CAUTION empty fuel tank.
sunlight and moisture.
(2). Refuel helicopter as required.
7. Fuel System Air Bleed (Model 250C30
Engine Installation) (a). Connect battery.
Fuel/air vapor discharged (b). Open engine access doors.

WARNING during bleeding is a fire haz-
(c). In crew compartment; push FUEL
ard. Prevent fuel vapor accumulation, shutoff valve knob in to open shutoff
ignition and fire. Perform work in an valve.
open, well ventilated area away from
all potential ignition sources. Attach (d). Set helicopter master switch to
helicopter to an approved electrical BATTERY.
ground. Wear approved eye protection.
(e). Set START PUMP switch ON to
(1). Helicopters with C30 engines fuel pressurize fuel system. Check; start
supply systems are not equipped with a pump is operating.
start pump. However, the helicopter
fuel system has an engine driven self
NOTE: Refer to applicable Allison Engine Op-
eration and Maintenance Manual for specif-
priming pump that will fill the fuel
ic engine fuel system air bleed information.
system when the engine is motored
with the starter. Motor engine per the (f). Purge air from engine fuel system
appropriate Pilots Flight Manual. per Allison Engine Operation and
Maintenance Manual.
(2). Bleed air out of helicopter engine fuel
controls per Allison Engine Operation (3). Set START PUMP and battery
and Maintenance Manual. switches OFF.
Page 202
Revision 19 280000
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Shutoff Valve Control Cable (1). Thread cable assembly aft through
Replacement instrument panel or console, lockwash-
er, jamnut and grommets to fuel shutoff
A. Fuel Shutoff Valve Control Cable valve. Maintain a cable bend radius
Removal greater than 3.5 inches (8.89 cm).
(Ref. Figure 401) (2). Secure forward end of cable with
(1). Remove left fuel cell floor access panel. lockwasher and jamnut.
(2). Disconnect control wire from fuel (3). Slip control cable wire through fuel
shutoff valve swivel. shutoff valve lever swivel.
(3). Remove control cable tyraps and (4). Secure end of cable housing to cell cover
clamps. with a clamp, washer and screw.
(4). Remove instrument panel left fairing (5). Install remaining clamps and tyraps.
and lower cover panels (instrument
panel mounted). (6). Rig cable with shutoff valve lever hard
against open stop. Adjust cable to get a
(5). Completely back jamnut away from 0.0900.150 inch (2.2863.810 mm) gap
cable plunger housing (Ref. Figure 401, between bottom of control knob and
view A). cable housing end fitting. Tighten cable
swivel pinch nut. Install cotter pin.
(6). Remove straps securing cable in nose
(instrument panel mounted) or remove Control action must move valve
clamp in compartment under pilots CAUTION to full open against mechanical
seat (console mounted). stop without bottoming control knob on
NOTE: Attach a trace wire or cord to the valve cable housing. Control cable operation shall
end of the cable before pulling assembly out be smooth with no binding.
of the instrument panel. Trace will guide re- (7). Pull valve control knob out with a
placement cable into correct position. spring scale. Required valve actuation
(7). Pull cable assembly out through force to be not more than 12 pounds
washer, jamnut and instrument panel. (53.38 N).
B. Fuel Shutoff Valve Control Cable (8). Repair, adjust or replace valve control
Installation system components to meet force limit.
(Ref. Figure 401) (9). Reinstall left fuel cell floor access panel.
Pulling detent knob out of cable (10). Reinstall instrument panel left fairing
CAUTION housing two or more inches may and lower cover panels (instrument
result in loss of the detent ball. panel mounted).
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280000 Revision 19
MAINTENANCE MANUAL
DETENT RELEASE
DETENT RELEASE
CABLE PLUNGER
PLUNGER HOUSING DETENT BALL
0.0900.150 INCH PLUNGER HOUSING SPRING

(2.2863.810 MM)
INSTRUMENT PANEL
CABLE PLUNGER
INSTRUMENT PANEL
NUT
CABLE RIGGING
HOLE
OPEN LOCKWASHER
LEVER
CL VALVE CABLE HOUSING
CONTROL KNOB ASSEMBLY

CLOSED
FUEL SHUTOFF VALVE ORIENTATION
AND LEVER POSITIONS
(LOOKING DOWN)
CABLE WIRE
CONSOLEMOUNTED
CONTROL END CLAMP
INSTRUMENT
PANEL
GROMMET
FUEL SHUTOFF
CABLE
CLAMP
STRAP STA. 78.50
NYLON GROMMET
STA. 64.36
STRAP
BRACKET
CREW COMPARTMENT
FLOOR
FUEL SHUTOFF STRAP

CABLE STA. 50.50
G280001A
Figure 401. Fuel Shutoff Valve Cable Installation
Page 402
Revision 19 280000
MAINTENANCE MANUAL
2. Fuel Shutoff Valve Replacement (5). Unplug fuel quantity transmitter

connector from cell cover receptacle.
A. Fuel Shutoff Valve Removal
(Ref. Figure 402) (6). Unclamp and disconnect control cable
from fuel shutoff valve.
Avoid fuel vapor ignition
WARNING and fire. Use only nonspark-
(7). Unfasten and remove Sta. 91.00 and
ing tools and explosion proof work 102.00 left fuel cell cover support
lights. Attach helicopter to an ap- brackets.
proved electrical ground. Switch OFF
all electrical power. Disconnect exter-
nal power and battery before opening CAUTION
fuel system. Ensure work area is ade-
quately ventilated. D Do not strain or bend fuel quantity trans-
mitter float arm.
CAUTION D Handle fuel cell cover with care. Prying
D Air in fuel system may cause power cover from cell opening or rough handling
surges or flameout. Bleed off trapped air may damage seal or cell fitting.
after opening system at any point be-
tween fuel tank and engine fuel nozzle. (8). Remove fuel quantity transmitter
flange screws. Lift transmitter assem-
D Prevent fuel system contamination. In-
bly out of cover opening.
stall caps on the ends of hoses, tubes and
fittings as parts are removed. Bag and
identify small parts to prevent loss or (9). Unbolt cell access cover. Prop cover
damage. open with suitably padded blocks.
(1). Defuel helicopter. Drain remaining fuel (10). Using a backup wrench on valve,
from tank sump drain valve into a separate fuel supply hose from fuel
suitable container. shutoff valve.
(2). Remove left fuel tank access panel from
passenger/cargo compartment floor. (11). Remove fuel shutoff valve and attach-
ing hardware.
(3). Unclamp fuel supply tube between fuel
shutoff valve and Sta. 124.00 bulkhead B. Fuel Shutoff Valve Installation
elbow. Using backup wrench on bulk-
head elbow so it will not rotate, discon- (Ref. Figure 402)
nect and remove tube.
(4). With 250C20B/R2 Engine or 250C30 NOTE: Fuel shutoff valve installation steps are
Engine With Optional Maintenance given in Fuel Cell Cover Installation proce-
Fuel Pump: Unclamp start pump wire dures.
harness and disconnect plug from cell
cover receptacle. (Ref. Fuel Cell Cover Installation)
Page 403
280000 TR10002
MAINTENANCE MANUAL
SCREW, TORQUE; 2025 IN. LB

(2.26 2.82 NM) (TYP)
SETSCREW CABLE
(NOTE) WIRE
BOLT, TORQUE; 7090 IN. LB VALVE LEVER PIN
(7.91 10.17 NM) (TYP) AND SWIVEL
BUSHING
ELECTRICAL WIRING
HARNESS
ENGINE FEED HOSE
SUPPORT BRACKET (3 SHUTOFF VALVE TO
PLACES) FIREWALL
TUBE NUT, TORQUE;

230260 IN. LB (25.99 29.38 NM)
CONTROL
CABLE
CARGO ELECTRICAL CONNECTOR
COMPARTMENT
FLOOR
FUEL SHUTOFF VALVE

SEAL WASHER
JAMNUT, TORQUE; 240280 IN. LB
(27.1231.64 NM)
HOSE NUT, TORQUE; 230260 IN. LB FUEL QUANTITY
(25.9929.38 NM) TRANSMITTER
FUEL INLET HOSE
ELECTRICAL
RECEPTACLE ELECTRICAL
RECEPTACLE
START PUMP ELECTRICAL
WIRING HARNESS
NOTE:
REQUIRED AT LOCATION SHOWN.
G280002A
Figure 402. Left Fuel Cell Cover Installation
Page 404
Revision 19 280000
MAINTENANCE MANUAL
3. Fuel Tank Vent System Component (7). Remove vent tube/emergency valve
Replacement assembly attaching hardware. Remove
flexible tubing from lower vent tube tee.
WARNING and fire. Use only nonspark- (8). Rotate emergency shutoff valve inboard
ing tools and explosion proof work and slip assembly down over landing
lights. Attach helicopter to an ap- gear structure. Remove tube assembly
proved electrical ground. Switch OFF through controls access panel opening.
nal power and battery before opening (9). Unclamp flexible tubing from side vent
fuel system. Ensure work area is ade- fairing. Remove tubing through controls
quately ventilated. access opening.
Prevent fuel system contamina- B. Forward Vent Crossover Fitting Removal

CAUTION tion. Install caps on the ends of
hoses, tubes and fittings as parts are re- (Ref. Figure 403)
moved. Bag and identify small parts to pre-
(1). Unbolt forward vent crossover fitting
vent loss or damage.
flanges.
(1). Defuel helicopter. Drain remaining fuel
from tank sump drain valve into a (2). Remove fitting, clamps, seals and
suitable container. washers.
Prevent spontaneous com- (3). Cover cell vent fittings and aft vent line
WARNING bustion or explosion. Never tube openings.
use oxygen to purge or ventilate fuel C. Aft Vent Crossover Fitting Removal
tank or fuel system components. Fuel,
either vapor or liquid, will violently (Ref. Figure 403)
react with an oxygen rich atmosphere.
NOTE: Left and right fuel cell access covers
(2). Ventilate fuel tank with an inert gas, must be removed to get at aft vent crossover
such as nitrogen, or low pressure Utube attaching hardware.
compressed air applied through filler
neck. (1). Remove left and right fuel cell floor
access panels.
A. Vent Tube/Emergency Valve Assembly
Removal (2). Unclamp fuel supply tube between fuel
shutoff valve and Sta. 124.00 bulkhead
(Ref. Figure 403) elbow. Using backup wrench on bulk-
(1). Unbolt and remove right fuel cell access head elbow so it will not rotate, discon-
cover. nect and remove tube.
(2). Remove right foot support, controls, (3). With 250C20 Series Engines or
and fuel vent access panels. 250C30 Engine With Optional Mainte-
nance Fuel Pump: Unclamp start pump
(3). Remove right seat from crew compart- wire harness and disconnect plug from
ment. cell cover receptacle.
(4). Move collective pitch stick full down. (4). Unplug fuel quantity transmitter
(5). In passenger/cargo compartment;
remove right and left fuel tank floor (5). Unclamp and disconnect control cable
access panels. from fuel shutoff valve.
(6). Remove lockwire from vent connector (6). Unfasten and remove Sta. 91.00 and
hoses and main rotor mast pan drain 102.00 left fuel cell cover support
tube. brackets.
Page 405
280000 TR10002
MAINTENANCE MANUAL
PAN
DRAIN TUBE
LOCKWIRE
CLIP
(2 PLACES)
BOLT
WASHER
LACING CORD
(TYPICAL)
WASHER
BOLT
CLAMP
BOLT WASHER
WASHER NUT
FROM AFT VENT
VENT TUBE
SCREW
LOCKWIRE
(TYPICAL) WASHER
CONNECTOR HOSE BOLT, TORQUE; 3646 IN. LB
SIDE VENT FAIRING (NOTE 2) (4.065.20 NM)
WASHER
CLAMPS
SCREW
SUPPORT COIL CLIP
WASHER
ANTISIPHON FUEL VENT

HOLES COVER
INTERCONNECT
FLEXIBLE TUBING FITTING
(NOTE 1)
SEAL WASHER
STANDOFF SEAL WASHER
WASHER (TYP)
LOWER VENT FAIRING
FWD INTERCONNECT AND NOTES:

EMERGENCY VALE ASSY 1. ROUTED THRU LANDING GEAR BRACE.
2. NOT TO BE PAINTED.
G2800031B
Figure 403. Vent System (Sheet 1 of 2)
Page 406
Revision 19 280000
MAINTENANCE MANUAL
VALVE CLOSED WHEN TILT

EXCEEDS 45 FROM VERTICAL CLAMP INTERCONNECT
OVERBOARD
HOSE
VALVE SEAT
SEAL WASHER
VALVE
CELL
TUBE (REF)
WEIGHT
FUEL VENT
IN NUT, TORQUE; 4060 IN. LB
(4.526.78 NM)
G2800032B
EMERGENCY VENT AFT INTERCONNECT
SHUTOFF VALVE
Figure 403. Vent System (Sheet 2 of 2)

(12). Cap tube and cell openings.
CAUTION
(13). Inspect all vent system components
D Do not strain or bend fuel quantity trans- (Ref. Fuel Tank Vent System Inspec-
mitter float arm. tion).
D Do not damage cell cover bonded seal. D. Fuel Tank Vent System Installation
Handle fuel cell covers with care. Prying
covers from cell openings or rough handl- (Ref. Figure 403)
ing may damage seal or cell fitting.
(7). Remove fuel quantity transmitter (Ref. Section 910000)
flange screws. Lift transmitter assem- Item Nomenclature
CM124 Kerosene
(8). Unbolt and prop fuel cell access cover
open with suitably padded blocks. Avoid fuel vapor ignition
(9). Use a backup wrench on valve and ing tools and explosion proof work
separate fuel supply hose from fuel lights. Attach helicopter to an ap-
shutoff valve. Move fuel cell cover to get proved electrical ground. Switch OFF
at remaining hardware. all electrical power. Disconnect exter-
nal power and battery before opening
(10). Reach back inside cells and remove fuel system. Ensure work area is ade-
vent interconnect nuts. Separate aft quately ventilated.
Utube interconnect from cells.
(1). Wipe forward and aft cell vent
(11). Unclamp and remove hose between fittings and crossover tube flanges
Utube interconnect tee and straight clean with kerosene (CM124) or
tube. Remove Utube interconnect. equivalent on a clean shop towel.
Discard sealwashers. Wipe dry.
Page 407
280000 Revision 19
MAINTENANCE MANUAL
NOTE: Do not lubricate fitting sealwashers. E. Vent Tube/Emergency Valve Assembly

Lubricants may cause seal cold flow and Installation
subsequent leakage.
(Ref. Figure 403)
(2). Install new sealwashers on aft vent
tube ends. Insert tube ends through cell (1). Move collective pitch stick full down.
fittings. Reach inside cell and install
(2). Remove protective covers from fittings
nuts.
and tubes.
(3). Torque aft vent Utube interconnect
(3). Work emergency valve and vent tube
nuts to 40 60 inchpounds (4.52
assembly through landing gear brace
6.78 Nm).
then into position in tunnel.
(4). Install hose and clamps between
interconnect Utube and straight tube. (4). Insert vent tube assembly in bottom
vent fairing.
(5). Position new sealwashers on cell
forward vent fittings. Slip vent tube (5). Loosely install vent tube support
into cell fitting. clamps, washers and bolts.
NOTE: Permatex FormAGasket No.1 may be (6). Install flexible tubing between side vent
used to hold metal standoff washers in fairing and vent tube assembly tee.
place. (7). Clamp flex tube ends in position with
(6). Sandwich one AN96010 washer on two or three wraps of lockwire.
each side of seal washer between vent (8). Tighten vent tube assembly support
tube flanges and cell fittings. Align clamp and bracket fasteners.
washers with bolt holes. Install bolts
with one washer under each bolt head. (9). Install and secure remaining vent
system connector hoses with lockwire.
(7). Torque forward vent interconnect tube
flange bolts to 36 46 inchpounds (10). Operate all flight controls through full
(4.07 5.20 Nm). range of motion to ensure no interfer-
ence exists between control linkages
(8). Connect powerplant supply tube to Sta.
and vent system. No interference is
124.00 bulkhead elbow. Loosely install
allowed. Adjust vent system hardware
tube support clamps, screws, washers
as required.
and nuts. Using backup wrench on
bulkhead elbow so it will not rotate, (11). Install fuel vent access panel.
torque tube nut to 230 260 inch
pounds (25.99 29.38 Nm). (12). Install controls access and foot support
panels.
(9). Install fuel cell covers (Ref. Fuel Cell
Cover Installation). (13). Install crew seat.
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Revision 19 280000
MAINTENANCE MANUAL
4. Fuel Supply Lines Replacement (4). Apply a torque alignment stripe to fuel
line tube, hose and fitting fasteners.
A. Fuel Supply Lines Removal
(Ref. Figure 404) 5. Start Pump Replacement (Model
250C20B/R2 / 250C30 Engine Installation)
WARNING and fire. Use only nonspark- NOTE: Use these start pump removal and
ing tools and explosion proof work installation procedures for helicopters with
lights. Attach helicopter to an ap- 250C30 engines equipped with optional
proved electrical ground. Switch OFF maintenance fuel pump.
nal power and battery before opening A. Start Pump Removal
quately ventilated. (Ref. Figure 404)
CAUTION WARNING and fire. Use only nonspark-
D Air in fuel system may cause power ing tools and explosion proof work
surges or flameout. Bleed off trapped air lights. Attach helicopter to an ap-
after opening system at any point be- proved electrical ground. Switch OFF
tween fuel tank and engine fuel nozzle. all electrical power. Disconnect exter-
D Prevent fuel system contamination. In- fuel system. Ensure work area is ade-
stall caps on the ends of hoses, tubes and quately ventilated.
identify small parts to prevent loss or Prevent fuel system contamina-
damage. CAUTION tion. Install caps on the ends of
hoses, tubes and fittings as the parts are re-
from tank sump drain valve into a
suitable container.
(2). Disconnect, remove and cap fittings and (1). Defuel helicopter. Drain remaining fuel
lines as required. from tank sump drain valve into a
suitable container.
B. Fuel Supply Lines Installation
(2). Remove left fuel tank access panel from
(Ref. Figure 404) passenger/cargo compartment floor.
(1). Install and torque engine fuel supply
(3). Unclamp fuel supply tube between fuel
lines (Ref. Table 401).
shutoff valve and Sta. 124.00 bulkhead
NOTE: It may be necessary to install a peelable elbow. Using backup wrench on bulk-
shim washer between the Sta. 124.00 fire- head elbow so it will not rotate, discon-
wall and the bulkhead elbow washer to ob- nect and remove tube.
tain the proper clocking angle and clearance
needed for line installation. (4). Unclamp start pump wire harness and
disconnect plug from cell cover recep-
(2). Install Sta. 124.00 firewall elbow, with tacle.
jam nut on forward side of firewall, flat
of nut against stiffener, and washer (5). Unplug fuel quantity transmitter
against elbow. Torque elbow to 145 connector from cell cover receptacle.
155 inchpounds (16.38 17.51 Nm).
Ensure elbow is clocked 12 16 to the (6). Unclamp and disconnect control cable
right from vertical after torquing. from fuel shutoff valve.
(3). Connect flexible drain lines to drain (7). Unfasten and remove Sta. 91.00 and
valves and clamp in place with lock- 102.00 left fuel cell cover support
wire. brackets.
Page 409
280000 TR10002
MAINTENANCE MANUAL
Table 401. Fuel Line Torque Values

Torque
Item/Position InchPounds (Nm)
Tube endnuts; fuel shutoff valve; Sta. 124.00 Bulkhead elbow 230 260 (25.99 29.38)
Bulkhead elbow jamnut; Sta. 124.00 145 155 (16.38 17.51)
Threeport elbow jamnut; Sta. 124.00 (if equipped) 145 155 (16.38 17.51)
Drain valves (all) 95 105 (10.73 11.86)
Hose endnuts; firewall/engine 230 260 (25.99 29.38)
pressure port union threads. Install

CAUTION Oring on union. Install union in start
D Do not strain or bend fuel quantity trans- pump pressure port and torque to 280
mitter float arm. 305 inchpounds (31.64 34.46 Nm).
D Handle fuel cell covers with care. Prying (2). Attach fuel supply hose to start pump
covers from cell openings or rough handl- pressure port union. Torque hose nut to
ing may damage the cover seal or cell fit- 230 260 inchpounds (25.99 29.38
ting. Nm).
(8). Remove fuel quantity transmitter
flange screws. Lift transmitter assem- CAUTION
D Ensure start pump wire lead is wrapped
(9). Unbolt and prop fuel cell access cover around or tiewrapped to fuel supply hose
open with suitably padded blocks. so that there is no possibility of its interf-
ering with fuel quantity transmitter float
(10). Use a backup wrench on valve and mechanism. Ensure electrical connec-
separate fuel supply hose from fuel tions will not be strained by Ginduced
shutoff valve. hose movements.
(11). Remove pump electrical receptacle from D Do not mark torque alignment stripes on
cover. Remove fuel cell cover. fuel cell internal hardware.
(12). Unbolt fuel pump from sump mount NOTE: Use only MS3367 tyraps inside fuel
plate. Remove fuel pump and hose. tanks.
(13). Remove hose and union from pump (3). Tiewrap or wrap pump wire around
pressure port. supply hose. Secure wire with tyraps
as required.
B. Start Pump Installation
(Ref. Figure 404) (4). Clean start pump and sump plate
mount contact surfaces to establish an
electrical bond per requirements of FAA
Consumable Materials publication, EAAC43.131A and 2A.
Item Nomenclature (5). Install start pump on sump plate with
CM114 Petrolatum bolts and washers. Torque bolts to 36
46 inchpounds (4.07 5.20 Nm).
(1). Apply a thin coat of petrolatum (6). Install fuel cell cover (Ref. Fuel Cell
(CM114) to a new Oring and pump Cover Installation).
Page 410
Revision 19 280000
MAINTENANCE MANUAL
TO ENGINE
HOSE AND FIRE

SLEEVE
WASHER
SHIM WASHER
(AS REQD)
NUT
HOSE ELBOW
STA 124.00
BULKHEAD
SUPPLY TUBE
HOSE
FUEL SUPPLY LINES INSTALLATION
BOLT, TORQUE; 3646 IN. LB

HOSE NUT, TORQUE; (4.065.20 NM)
230260 IN. LB
(25.9929.38 NM)
WASHER
UNION, TORQUE;
280305 IN. LB
(31.6434.46 NM) FUEL PICKUP FITTING
START PUMP
ORING HOSE NUT, TORQUE;
230260 IN. LB
(25.9929.38 NM) BOLT, TORQUE; 3646 IN. LB
TANK SUMP PLATE (4.065.20 NM)
STRUCTURE
UNION, TORQUE;
280305 IN. LB
(31.6434.46 NM)
WASHER
FUEL CELL ORING
ORING
TANK SUMP PLATE
TANK SUMP DRAIN VALVE,
TORQUE; 95105 IN. LB
(10.7311.86 NM)
WASHER
BOLT, TORQUE; 3646 IN. LB

(4.065.20 NM)
FUEL PICKUP INSTALLATION (369FF) ORING
WASHER
TANK SUMP DRAIN VALVE,
BOLT, TORQUE; 3646 IN. LB TORQUE; 95105 IN. LB
(4.065.20 NM) (10.7311.86 NM)
START PUMP INSTALLATION
G2800041C
Figure 404. Start Pump and Fuel Lines Installation (Sheet 1 of 4)
Page 411
280000 Revision 19
MAINTENANCE MANUAL
TOP VIEW
FUEL HOSE BATHTUB FITING
START PUMP WIRE

FLOAT ASSEMBLY
START PUMP
SIDE VIEW
NOTE:
WRAP WIRE AROUND FUEL INLET HOSE TO PREVENT
INTERFERENCE WITH FLOAT.
G2800042
Page 412
Revision 19 280000
MAINTENANCE MANUAL
TOP VIEW
FUEL HOSE
BATHTUB FITING
START PUMP WIRE FLOAT ASSEMBLY
START PUMP
SIDE VIEW
NOTE:
G2800043
Page 413
280000 Revision 19
MAINTENANCE MANUAL
TOP VIEW
FUEL HOSE BATHTUB FITING
START PUMP WIRE

FLOAT ASSEMBLY
START PUMP
SIDE VIEW
NOTE:
G2800044
Page 414
Revision 19 280000
MAINTENANCE MANUAL
6. Fuel Quantity Transmitter Replacement (7). Calibrate quantity transmitter as

required (Ref. Fuel Quantity Transmit-
A. Fuel Quantity Transmitter Removal ter Calibration and Adjustment).
(Ref. Figure 404) B. Fuel Quantity Transmitter Installation
Avoid fuel vapor ignition (Ref. Figure 404)
ing tools and explosion proof work Consumable Materials
lights. Attach helicopter to an ap- (Ref. Section 910000)
proved electrical ground. Switch OFF Item Nomenclature
nal power and battery before opening CM124 Kerosene
quately ventilated. (1). Wipe fuel quantity transmitter flange
and cell fitting clean with kerosene
(CM124) on a clean lint free cloth. Wipe
parts dry.
suitable container.
(2). Position fuel quantity transmitter and
Prevent spontaneous com- flange gasket on cell with float inboard
WARNING bustion or explosion. Never
and clear of obstructions.
use oxygen to purge or ventilate fuel
tank or fuel system components. Fuel, (3). Install screws and washers. Progres-
either vapor or liquid, will violently sively torque screws to 20 25 inch
react with an oxygen rich atmosphere. pounds (2.26 2.82 Nm). Lockwire
screws.
(2). Ventilate fuel tank with an inert gas
such as nitrogen or low pressure (4). Attach fuel quantity electrical connec-
compressed air applied through filler tor to receptacle. Lockwire connector.
neck.
(5). Perform a Fuel Quantity Transmitter
(3). Remove left fuel tank access panel from Functional Check.
passenger/cargo compartment floor.
(6). Install left fuel tank floor access panel
(4). Unplug fuel quantity transmitter (Ref. Fuel Cell Cover Installation).
7. Fuel System Drain Valve Replacement
Unclamp wire harness.
A. Fuel System Drain Valve Removal
CAUTION Avoid fuel vapor ignition
D Do not strain or bend fuel quantity trans-
mitter float arm. ing tools and explosion proof work
lights. Attach helicopter to an ap-
D Prevent fuel system contamination. In- proved electrical ground. Switch OFF
stall a cover over quantity transmitter all electrical power. Disconnect exter-
cell opening. Bag small parts to prevent nal power and battery before opening
loss or damage. fuel system. Ensure work area is ade-
quately ventilated.
(5). Remove fuel quantity transmitter
flange screws. Lift transmitter assem- Helicopter must be defueled and
bly out of cover opening. Discard CAUTION drained prior to removing tank
gasket. sump drain valve.
(6). Inspect fuel quantity transmitter as (1). Defuel helicopter, as required. Drain
required (Ref. Fuel Quantity Transmit- remaining fuel from tank sump drain
ter Inspection). valve into a suitable container.
Page 415
280000 Revision 36
MAINTENANCE MANUAL
(2). Remove lockwire from tank sump drain A. Fuel Cell Removal
valve.
(3). Using appropriate socket or wrench,
remove drain valve. ing tools and explosion proof work
lights. Attach helicopter to an ap-
B. Fuel System Drain Valve Installation proved electrical ground. Switch OFF
Consumable Materials fuel system. Ensure work area is ade-
(Ref. Section 910000) quately ventilated.
Item Nomenclature
Prevent fuel system contamina-
CM114 Petrolatum CAUTION tion. Install caps on the ends of
CM124 Kerosene hoses, tubes and fittings as parts are re-
CM702 Lockwire CRES moved. Bag and identify small parts to pre-
(1). Replace drain valve Oring packings. from tank sump drain valve into a
Lubricate packings with kerosene suitable container.
(CM124), petrolatum (CM114) or jet
fuel. Prevent spontaneous com-
(2). Install and torque sump drain valve to use oxygen to purge or ventilate fuel
95 105 inchpounds (10.73 11.86 tank or fuel system components. Fuel,
Nm). Lockwire valve. either vapor or liquid, will violently
(3). Apply a torque alignment stripe to fuel
(2). Ventilate fuel tank with low pressure
forced air or an inert gas such as
(4). Refuel helicopter. nitrogen through filler neck.
(3). Remove right and left fuel tank access
(5). Check drain valve for leakage. panels from passenger/cargo compart-
ment floor.
(6). Apply external power.
NOTE: The following procedures are required
(7). In crew compartment; set battery to access and separate the fuel cell intercon-
switch to EXT PWR position. nect fitting and vent system aft crossover
before either cell can be removed from its
(8). Push fuel shutoff valve control knob in bay.
to open valve. (4). Unclamp fuel supply tube between fuel
shutoff valve and firewall Sta. 124.00
(9). With 250C20B/R2 Engine: Set START
bulkhead elbow. Using a backup
PUMP switch ON to pressurize fuel
wrench on bulkhead elbow so it will not
system.
rotate, disconnect and remove tube.
8. Fuel Cell Replacement (5). With 250C20B/R2 Engine or 250C30
Engine With Optional Maintenance
Fuel Pump: Unclamp start pump wire
CAUTION harness and disconnect plug from cell
cover receptacle.
D Do not work on Uniroyal fuel cell in ambi-
ent temperatures below 50F (10C). (6). Unplug fuel quantity transmitter
D Do not work on Engineering Fabric Corp.
fuel cell in ambient temperatures below (7). Unclamp and disconnect control cable
70F (21C). from fuel shutoff valve.
Page 416
TR10002 280000
MAINTENANCE MANUAL
(8). Unfasten and remove Sta. 91.00 and NOTE: At this point either cell may be re-
102.00 left fuel cell cover support moved, as required.
brackets from airframe structure.
(19). Remove left fuel cell as follows:
CAUTION (a). Remove cell suspension cords (Ref.
Figure 406).
D Do not strain or bend fuel quantity trans-
mitter float arm. (b). Remove and discard forward and aft
D Handle fuel cell covers with care. Prying vent sealwashers.
covers from cell openings or rough handl- (c). Lift inboard and outboard cell clips at
ing may damage the cover seal or cell fit- each end of baffle support rod out of
ting. airframe hangers (Ref. Figure 405).
(9). Remove fuel quantity transmitter (d). Inside cell, work baffle support rod
flange screws. Lift transmitter assem- ends out of cell nipples (Ref.
bly out of cover opening. Figure 405, detail B).
(10). Unbolt and prop fuel cell access cover (e). Remove support rod and baffle.
open with suitably padded blocks.
Cells are thinwalled and frag-
(11). Using a backup wrench on valve, CAUTION ile. Avoid snagging or dragging
separate fuel supply hose from fuel cell over pointed or sharp edges. Do not
shutoff valve. Move fuel cell cover to get scratch or nick any of the cells metal fit-
at remaining hardware. tings.
(12). With 250C20B/R2 Engine or 250C30 (f). Collapse and fold cell lengthwise and
Engine With Optional Maintenance remove through floor access opening.
Fuel Pump: Unbolt start pump from
sump mount plate. Remove start pump, (20). Remove right fuel cell as follows:
hose and cell cover. Remove pump
electrical receptacle from cover. (a). Remove fuel filler cap and shield.
Unclamp and remove filler from cell
(13). With 250C30 Engine: Unbolt fuel inlet filler neck.
fitting from sump plate. Remove fuel
inlet fitting, hose and cell cover. (b). Remove cell suspension cords.
(14). Unbolt and remove right fuel cell access (c). Remove and discard forward and aft
cover. vent sealwashers.
(d). Lift inboard and outboard cell clips at
(15). Mop up any remaining fuel in both cells each end of baffle support rod out of
with clean lint free cloth. Purge fuel airframe hangers.
cells with dry, forced air or inert gas.
(e). Inside cell, work baffle support rod
(16). Have an assistant hold the male end of ends out of cell nipples.
the cell interconnect fitting with the
special spanner wrench. Disassemble (f). Remove support rod and baffle.
fuel cell interconnect fitting (Ref.
Figure 405). Discard packing. Cells are thinwalled and frag-
CAUTION ile. Avoid snagging or dragging
(17). Remove aft vent crossover Utube nuts cell over pointed or sharp edges. Do not
from inside cells. scratch or nick any of the cells metal fit-
tings.
(18). Remove forward vent crossover tube
flange bolts and washers (Ref. (g). Collapse and fold cell lengthwise and
Figure 403). remove through floor access opening.
Page 417
280000 TR10002
MAINTENANCE MANUAL
B. Fuel Cell Installation (6). Insert baffle rod ends in nipples.

(7). Attach baffle external support hooks to
Consumable Materials airframe hangers.
Item Nomenclature (8). Wipe cell forward and aft vent fittings
and vent tube flanges clean with
CM114 Petrolatum
kerosene (CM124) or equivalent on a
CM124 Kerosene clean shop towel. Wipe dry.
CM809 Nylon cord
NOTE: Do not lubricate fitting sealwashers.
Lubricants may cause seal cold flow and
Special Tools
subsequent leakage.
Item Nomenclature (9). Install new sealwashers on aft vent
ST802 Spanner wrench tube ends. Insert tube ends through cell
fittings and install nuts finger tight. Do
not torque at this time.
WARNING and fire. Use only nonspark- (10). Position new sealwashers on cell
ing tools and explosion proof work forward vent fittings. Slip cell fitting
lights. Attach helicopter to an ap- over vent tube.
proved electrical ground. Switch OFF NOTE: Permatex FormAGasket No. 1 may
all electrical power. Disconnect exter- be used to hold standoff washers in place.
fuel system. Ensure work area is ade- (11). Sandwich one AN96010 washer on
quately ventilated. each side between vent tube flanges
and cell fittings. Align washers with
NOTE: bolt holes. Install bolts with one washer
D Discard used Orings and sealwashers. under each bolt head and engage
Apply a thin coat of petrolatum (CM114) several threads to keep bolt in place. Do
to all new Orings except cell vent system not torque bolts at this time.
sealwashers and interconnect fitting gas-
ket. (12). Fasten fuel cell sump plate to airframe
with washers and bolts. Torque bolts to
D Always test and inspect a repaired fuel 36 46 inchpounds (4.07 5.20
cell for leaks using soap bubble, phe- Nm). Lockwire bolts.
nolphthalein or liquid stand method be-
fore installing the cell in the helicopter. (13). Install a new Oring on sump drain
valve. Install valve and torque to 95
(1). Airvacuum all debris from cell bays. 105 inchpounds (10.73 11.86 Nm).
Ensure compartment liner will protect Lockwire valve.
cell from airframe points and edges.
Repair liner as required. NOTE: Do not lubricate fuel cell interconnect
fitting gasket. Lubrication may cause seal
(2). Wipe left and right cell interconnect cold flow and subsequent leakage.
fitting halves clean with kerosene
(CM124) on a clean lint free shop towel. (14). Thread gasket and nut onto cell
Wipe dry. interconnect fitting. While having an
assistant hold the opposite end of
(3). Fold cell lengthwise and position in bay fitting with spanner wrench (ST802)
through floor opening and unfold cell. tighten nut. Gap between nut and
female fitting shall not be more than
(4). Align cell openings with airframe 0.005 inch (0.127 mm) after tightening.
openings.
(15). Connect powerplant supply tube to
(5). Insert baffle support rods through firewall Sta. 124.00 bulkhead elbow.
baffle tabs (Ref. Figure 405).. Loosely install tube support clamps,
Page 418
Revision 19 280000
MAINTENANCE MANUAL
screws, washers and nuts (Ref. (24). Install filler on right fuel cell filler neck
Figure 404, detail A). Using a backup with clamp and fuel filler shield. Install
wrench on bulkhead elbow so it will not filler cap (Ref. Figure 405).
rotate, torque tube nut to 230 260
inchpounds (25.99 29.38 Nm). C. Fuel Cell Cover Installation
(16). Torque aft vent Utube interconnect Consumable Materials

nuts to 40 60 inchpounds (4.52 (Ref. Section 910000)
6.78 Nm). Item Nomenclature
CM114 Petrolatum
(17). Torque forward vent interconnect tube
flange bolts to 36 46 inchpounds CM124 Kerosene
(4.07 5.20 Nm) (Ref. Figure 403).
(1). Inspect both cell cover seals for debond-
(18). Install nylon support lacing (CM809). ing, nicks or cuts and any other damage
Anchor both ends of cord with a bowline having a leak producing potential.
knot (Ref. Figure 406). Replace covers as required.
(19). With 250C20B/R2 Engine or 250C30 (2). Wipe fuel cell and cover sealing sur-
Engine With Optional Maintenance faces clean with kerosene (CM124) on a
Fuel Pump: Install union in start pump clean lint free cloth.
pressure port with a new Oring
packing. Torque union to 280 305 (3). Install right cell cover bolts and
inchpounds (31.64 34.46 Nm) (Ref. washers (Ref. Figure 405). Progressive-
Figure 404, detail B). Attach fuel ly torque cover bolts to 70 90 inch
supply hose to start pump pressure port pounds (7.91 10.17 Nm) in a cross
union. Torque hose nut to 230 260 pattern.
(4). Apply a coating of petrolatum (CM114)
Ensure start pump wire lead is to a new fuel shutoff valve/cover
CAUTION wrapped around or tiewrapped sealwasher. Install valve on cell cover
(using only MS3367 TyRaps) to fuel supply with sealwasher next to valve body and
hose so that there is no possibility of its in- valve properly aligned to make connec-
terfering with fuel quantity transmitter tion with valve control cable. Install
float mechanism. Ensure electrical connec- and torque valve jamnut to 240 280
tions will not be strained by Ginduced hose inchpounds (27.12 31.64 Nm) (Ref.
movements. Figure 402).
(5). With 250C20B/R2 Engine or 250C30
(20). Wrap pump wire around supply hose or
Engine With Optional Maintenance
secure wire with tyraps as required.
Fuel Pump: Plug start pump wire
harness cell cover hole with a bulkhead
(21). Clean start pump and sump plate union, sealwasher inside cover and a
mount contact surfaces to establish an plain washer outside. Install jamnut
electrical bond per requirements of FAA and torque to 120 150 inchpounds
publication, EAAC43.131A and 2A. (13.56 16.95 Nm). Install cap outside
of cell. Torque cap to 120 150 inch
(22). Install start pump on sump plate with pounds (13.56 16.95 Nm).
bolts and washers. Torque bolts to 36
46 inchpounds (4.07 5.20 Nm). (6). Position cover over cell opening.
Connect fuel supply hose to fuel shutoff
(23). With 250C30 Engine: Attach fuel inlet valve. Torque hose nut to 230 260
fitting to cell sump plate with bolts and inchpounds (25.99 29.38 Nm).
washers. Torque bolts to 36 46 Ensure hose will not be twisted when
inchpounds (4.07 5.20 Nm). cover is installed.
Page 419
280000 TR10002
MAINTENANCE MANUAL
0.005 IN. (0.127 MM) MAXIMUM GAP

BETWEEN NUT AND FITTING
CELL INTERCONNECT NUT

FITTING
GASKET HELICOPTER
CL
BAFFLE NIPPLE
SUPPORT ROD
FUEL CELL INTERCONNECT

BOLT, TORQUE;
7090 IN. LB
(7.9110.17 NM)
FILLER GROMMET
FUEL FILLER CAP BAFFLE SUPPORT HOOK
RIGHT FUEL CELL

ACCESS COVER FUEL FILLER SHIELD FUEL
CELL
BAFFLE SUPPORT ROD FUEL TANK FILLER NECK
(2) (TYP)
AFT VENT CELL BAFFLE SUPPORT
INTERCONNECT (CROSS SECTION VIEW)
CLAMP
NYLON CELL TANK BAFFLE

SUPPORT LACING (TYP)
(TYP)
STA. 124.00
NUT BULKHEAD
CLAMP
(TYP)
VENT TUBE CELL INTERCONNECT LEFT FUEL CELL

EMERGENCY FITTING ACCESS COVER
VALVE ASSY
FUEL INLET HOSE
RIGHT CELL TUBE

UNION
FWD VENT CELL
INTERCONNECT POWER PLANT
SUPPLY TUBE
LEFT CELL
START PUMP
(369D/E 500N)
GASKET TANK SUMP PLATE

NUT
G280005C
Figure 405. Fuel Cells
Page 420
Revision 19 280000
MAINTENANCE MANUAL
CELL TOP ATTACHMENT

(TYP)
CELL SIDE ATTACHMENT

(TYP)
BOWLINE KNOT
START LACING WITH
BOWLINE KNOT
(FOLLOW ARROWS) TOP OF CELL
END LACING WITH NYLON LACING

BOWLINE KNOT
NYLON LACING
LOOP
START LACING WITH

BOWLINE KNOT
(FOLLOW ARROWS)
END LACING WITH

BOWLINE KNOT G280006
Figure 406. Fuel Cell Support Lacing
(7). With 250C20B/R2 Engine or 250C30 (12). Inspect fuel quantity transmitter flange
Engine With Optional Maintenance gasket for condition. Replace gasket if
Fuel Pump: Install start pump wiring damaged or deteriorated. Position fuel
harness receptacle on fuel cell cover. quantity transmitter in cell with float
inboard and clear of obstacles. Install
(8). Install three support brackets on Sta. screws and washers. Progressively
91.00 and 102.00 floor crossmembers torque screws to 20 25 inchpounds
with washers and screws. Torque (2.26 2.82 Nm). Lockwire screws.
screws to 20 25 inchpounds (2.26
2.82 Nm).
(13). Torque power plant fuel supply tube
(9). Finger tighten fuel supply tube nut nut to 230 260 inchpounds (25.99
onto fuel shutoff valve. Position control 29.38 Nm). Tighten supply tube clamp
cable and electrical harness clamps on fasteners.
cover.
(14). Slip control cable through hole in fuel
(10). Install cover bolts and washers. Install shutoff valve lever swivel.
drilledhead bolt one bolt hole inboard
of pump electrical receptacle. Progres-
(15). Rig cable control system (Ref. Fuel
sively torque cover bolts to 70 90
Shutoff Valve Control Cable Installa-
inchpounds (7.91 10.17 Nm) in a
tion).
cross pattern.
(11). Lockwire electrical receptacle nut to (16). Attach fuel quantity electrical connec-
drilled bolt. tor to receptacle. Lockwire connector.
Page 421
280000 TR10002
MAINTENANCE MANUAL
(17). With 250C20B/R2 Engine or 250C30 (19). With 250C20B/R2 Engine or 250C30
Engine With Optional Maintenance Engine With Optional Maintenance
Fuel Pump: Attach start pump electri- Fuel Pump: Perform a start pump
cal connector to receptacle. Lockwire operation and system pressurization
connector. check with a concurrent leak inspection
(Ref. Start Pump Operational Check
NOTE: To ensure that the C30 engine installa- (Model 250C20 Series Engines).
tion fuel system is free of leaks you must
(20). Apply a torque alignment stripe to fuel
perform a vacuum leak test.
(18). Perform a vacuum leak inspection on (21). Install left and right cell access panels
all helicopter models. on cargo compartment floor.
Page 422
TR10002 280000
MAINTENANCE MANUAL
FUEL SYSTEM
ADJUSTMENT/TEST
1. Fuel Level Low Caution Light System Test previously installed, replace quantity
transmitter and calibrate system.
Special Tools (8). Remove left fuel cell floor access panel.
Item Nomenclature (9). Ground fuel quantity transmitter
terminal No. 2 to airframe with a
N/A Inclinometer, Sperry Model 45
jumper wire.
(10). FUEL LEVEL LOW caution lamp
WARNING should show a steady bright light.
D FUEL LEVEL LOW warning lighton (11). If the light is intermittent or does not
point, either 35 pounds for commer- come on at all, disconnect all power and
cial helicopters or 70 pounds fuel re- run a continuity check on the warning
maining for noncommercial ma- light and wiring between the INSTR
chines, must comply with the fuel circuit breaker and transmitter.
low level caution light calibration (12). If the wiring and light check out,
specified in the Pilots Flight Manual. remove and bench check the transmit-
D A 70 pound fuel level low warning ter assembly (Ref. Fuel Quantity
light calibration is not approved for Transmitter Calibration and Adjust-
commercial applications. ment).
(1). Refuel to bring fuel quantity above 35 2. Fuel Quantity Transmitter Calibration and
or 70 pound low level warning point, as Adjustment
appropriate.
(Ref. Figure 501)
(2). Plug in and switch on 24 28 Vdc
external power. Special Tools
(3). Set battery switch to EXT PWR. Item Nomenclature
(4). Reset INSTR circuit breaker. N/A Test harness and No. 328 lamp
(5). Set caution and warning light dimmer Prevent fuel vapor accumu-
control on BRT. WARNING lation, ignition and fire. At-
tach helicopter to an approved electri-
(6). Test caution and warning light array.
cal ground. Switch OFF and disconnect
Replace lamps as required.
external power and battery before
(7). With known fuel quantity above 35 or opening fuel system. Perform work in
70 pounds, caution lamp must be off. an open, well ventilated area away
Check warning light to ensure it does from all potential ignition sources. Use
not glow or flicker. A glowing caution only nonsparking tools and explosion
lamp with fuel quantity above the low proof work lights.
level warning point indicates that (1). Remove fuel quantity transmitter from
current is leaking past the low level tank. Install a cover on cell opening.
warning transistor (switch) through the
caution lamp. This problem is corrected (2). Fabricate a stand to support quantity
by installing a resistor in the transmit- transmitter level about 11 inches (28
ter warning light circuit (Ref. Fuel cm) above work table surface. Support
System Repairs). If resistor has been stand must allow access to float arm.
Page 501
280000 Revision 19
MAINTENANCE MANUAL
NO. 328 A R
LAMP B BLU
+ D RED
Q
24 VDC
POWER B
SUPPLY G
E BLK
H BLK
P251
CONNECTOR
FUEL QUANTITY
TRANSMITTER
TEST CONNECTIONS
1.75 IN. (4.45 CM)
DIA (MAX.
CONNECTOR SEALANT
ENVELOPE)
0.75 IN. (4.45 CM) MAX.

SEALANT ENVELOPE
FULL
FLOAT STOP (FULL)
SPRING 10.08 IN.

(25.60 CM)
BRACKET RADIUS
FLOAT STOP
(EMPTY)
8.999.11 IN.
(22.8423.134CM)
SPRING CONTACT
FLOAT 2.15 IN. (5.46 CM)
(NOTE 2)
A
GROUND TERMINAL
G
EMPTY
1.25 IN.
TRANSISTOR SWITCH (3.175 CM)
B (ON UNDERSIDE) (NOTE 1)
CALIBRATION 369A4245 (EARLY UNIT)
NOTES:
TANK UNIT 1. CAUTION LIGHT ON, 35 LBS REMAINING.
CONNECTIONS 2. CAUTION LIGHT ON, 70 LBS REMAINING.
NOT APPROVED FOR COMMERCIAL
APPLICATION. G2800071A
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 1 of 2)
Page 502
Revision 19 280000
MAINTENANCE MANUAL
0.62 IN.
CONNECTOR (15.75 MM)
MOUNTING FLANGE
FLOAT STOP FULL

(FULL)
BOTTOM OF FLOAT
10.08 IN.
(25.60 CM)
RADIUS
SPRING
FLOAT STOP
(EMPTY) 8.418.45 IN.
(21.3621.46 CM)
2.132.17 IN.
(5.415.51 CM)
SPRING CONTACT (NOTE 2)
(NOTE 1)
0.910.95 IN.
(23.1124.13 MM)
FLOAT
NOTES: EMPTY
1. CAUTION LIGHT ON, 35 LBS REMAINING.
2. CAUTION LIGHT ON, 70 LBS REMAINING.
NOT APPROVED FOR COMMERCIAL
APPLICATIONS. CALIBRATION 369D296303 (CURRENT UNIT) G2800072A
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 2 of 2)

A. Fuel Level Calibration (6). On part Nos. 369A4245 (early) and
369D296303 (current) transmitters:
(1). Let float arm rest on lower stop.
(a). Attach ohmmeter leads to connector
(2). Set an ohmmeter on its low resistance pins B and H.
scale. Measure resistance across
connector pins B and H. (b). Raise float arm against upper stop.
Part number 369A4245 (early) quantity (c). Indicated resistance shall be 88 95

transmitter resistance must be 0 3 ohms.
ohms. (d). Bend stop to adjust resistance value.
P/N 369D296303 (current) units must (e). Measure float travel between empty
register 0.10 2.00 ohms. and full stops. Ensure travel is
within limits (Ref. Figure 501).
(3). Bend float stop down to decrease, or up
to increase resistance. (7). Disconnect ohmmeter.
(4). Raise float arm to contact upper stop. B. Fuel Level Low Warning Light Calibration
(5). On 369A4245 (early) quantity transmit- (1). Fabricate test harness incorporating a
ters only, measure resistance between No. 328 lamp bulb and P251 female
steel wire spring support bracket and connector half. Alternatively, fabricate
mounting flange. Resistance must be test wires with individual insulated
greater than 2 megohms. tubular pin connectors.
Page 503
280000 Revision 19
MAINTENANCE MANUAL
(2). Attach test harness to transmitter (5). Check P/N 369D296303 and
connector pins D and H and power 369D296303701 (current) transmitter
source. units as follows:
(3). Switch on 24 Vdc power. (a). Hold float arm between stops. Test
lamp must be off. A glowing lamp
(4). Check P/N 369A4245 (early) transmit- indicates that current is leaking past
ter units as follows: transistor (lamp switch).
The problem is corrected by installing
(a). Hold float arm between stops. Test a 510 ohm resistor in the transmitter
lamp must be off. A glowing lamp caution light circuit (Ref. Fuel
indicates that current is leaking past System Repairs).
transistor (lamp switch). The prob-
lem is corrected by installing a 510 If resistor has been previously
ohm resistor in the transmitter installed, replace quantity transmit-
caution light circuit (Ref. Fuel ter.
System Repairs). If resistor has been
previously installed, replace quantity (b). Lower float arm to just touch bracket
transmitter. supported steel wire.
(b). Lower float arm until it just contacts (c). Test lamp should come on.
bracket supported steel wire: (d). Mark arm/float centerline position on
a ruler or stick where lamp comes on.
(c). Test lamp should come on.
(e). Lower float. Mark ruler at arm/float
(d). Mark arm/float centerline position on centerline position with float bot-
a ruler or stick at point where lamp tomed on stop.
comes on.
(f). Measured distance between upper
(e). Lower float. Mark ruler at arm/float and lower marks shall be:
centerline position with float bot- 0.91 0.95 inch (23.11 24.39 mm)
tomed on stop. for 35 pounds (nominal) fuel remain-
ing.
WARNING 2.13 2.17 inch (5.41 5.51 cm) for
D FUEL LEVEL LOW warning lighton 70 pounds (nominal) fuel remaining.
point, either 35 pounds for commer- (6). Bend transmitter bracket spring wire to
cial helicopters or 70 pounds fuel readjust lighton position as required.
maining for noncommercial ma-
chines, must comply with the fuel (7). Check that lamp operation and float
low level caution light calibration dimensions are within specified
specified in the Pilots Flight Manual. tolerances.
D A 70 pound fuel level low warning (8). Disconnect electrical power and test
light calibration is not approved for equipment.
commercial applications.
3. Fuel Quantity Transmitter Functional
(f). Distance between upper and lower Check
marks shall be:
1.25 inch (3.18 cm) for 35 pounds Special Tools

(nominal) fuel remaining. (Ref. Section 910000)
Item Nomenclature
2.15 inch (5.46 cm) for 70 pounds N/A Inclinometer, Sperry Model 45
(nominal) fuel remaining.
Page 504
Revision 19 280000
MAINTENANCE MANUAL
Avoid fuel vapor accumula- (12). Disconnect fuel supply hose from
WARNING tion, ignition and fire. Use engine.
only nonsparking tools and explosion
proof work lights. Attach helicopter to (13). Have an assistant direct fuel hose into
an approved electrical ground. Switch a suitable 10 gallon (37.85 L) container.
OFF all electrical power. Disconnect Push fuel control valve knob in to open
external power and battery before fuel shutoff valve.
opening fuel system. Ensure work area (14). (C20 Series Engines) Set fuel start
is adequately ventilated. pump switch to START PUMP.
(1). Attach helicopter to an approved (15). (C30 Engine) Attach a siphon pump to
electrical ground. fuel supply hose to suck fuel out of
tank.
(2). Defuel and drain fuel tank.
(16). Pump 0.5 1.5 gallons (1.89 5.68 L),
(3). Locate inclinometer on rear deck 3.0 10.0 pounds (1.36 4.54 kg) out of
between Sta. 100 and 104. the fuel tank while observing fuel
gauge for erratic or hung movement.
(4). Jack and level helicopter or spot Fuel quantity gauge needle shall range
helicopter on level ground. between 34 42 pounds.
(5). Jack helicopter to get a 2 nose down NOTE:
attitude on the inclinometer. Stabilize D (C20 Series Engines) A stuck needle on
helicopter with blocks as required. a new, calibrated and tested gauge may be
due to transmitter float contact with the
(6). Reset INST and PNL LT circuit
start pump wire, pump or supply hose.
breakers.
D (C30 Engine) Transmitter float interfer-
(7). Apply external power. Set battery ence may be caused by the supply hose or
switch to EXT PWR. sump pickup fitting.
NOTE: All gauge readings are taken from the (17). Loosen fuel quantity transmitter
centerline of the fuel quantity indicator mounting flange screws. Rotate
pointer. transmitter clockwise as far as it will
move and tighten screws. Check gauge
(8). Check that fuel quantity gauge needle needle position.
points to empty, E with the pointer
centerline between the outer and inner (18). If float interference problem persists,
edge of the E graduation mark. Check remove quantity transmitter and
that FUEL LEVEL LOW warning determine action required to eliminate
light is on. problem; i.e. reposition transmitter
float arm, fuel supply hose and, or start
NOTE: Do not bend float arm for adjustment of pump wire.
fuel quantity indicating system. (19). Install transmitter and repeat function-
(9). If adjustments are required; shut down al check.
external electrical power, and remove (20). When 10 pounds (4.54 kg), 1.53 gallons
transmitter, bend float stops as re- (5.79 L) has been pumped, needle
quired and reinstall transmitter. pointer should be aligned on center of
the 35 pound red dot mark and FUEL
(10). Pump seven gallons of fuel into tank. LOW caution light should come on.
(11). Apply external power. Set battery (21). Drain remaining fuel and observe that
switch to EXT PWR. gauge needle falls to empty (E) as tank
runs dry.
FUEL LEVEL LOW warning light
should be out, and gauge should (22). Repeat adjustments as required.
indicate approximately 45 pounds. Additional adjustments to float arm or
Page 505
280000 Revision 36
MAINTENANCE MANUAL
low level contact wire requires a (4). Disconnect hose from from switch
verification check and repetition of the bushing. Cap hose.
entire check procedure sequence.
(5). Remove fuel pressure switch with
(23). Connect fuel supply hose to engine inlet bushing intact from after filter (AF)
port. Torque hose nut to 230 260 port adapter. Install an Oring on a
inchpounds (25.99 29.38 Nm). suitable airtight plug and tighten into
adapter fitting.
(24). Install quantity transmitter (Ref. Fuel (6). Bench test 369H8144 bypass pressure
Quantity Transmitter Installation). switch as follows (denoted by three
housing screws):
4. Fuel Filter (Bypass) Caution Light
Pressure Switch Test (a). Assemble test equipment shown in
Figure 502. Connect tester to pres-
sure switch lead and connect ground
WARNING test lead to one of three screws on the
housing body.
D Air in the fuel system will cause a
power reduction or flameout. Do a (b). Remove bushing and Oring from
fuel system vacuum leak check and switch. Attach tubing to switch inlet
system air bleed after opening fuel port as shown. Wipe switch complete-
system to atmosphere and prior to ly dry so any leakage can be detected
releasing helicopter for flight. during the test.
D (Model 250C20 Series Engines) En- (c). Add fuel to tube. Ohmmeter must
sure start pump is operating before indicate switch contact closure as
taking fuel samples from system sup- fuel column height passes between
ply line drain valves. 24.5 and 35.0 inches (62.23 and 88.90
cm).
(1). Set all switches; OFF. Disconnect
external electrical power. Disconnect (d). Check switch for leakage around
battery. diaphragm. No leaks allowed.
Replace a leaking switch.
(2). Open engine access doors. (e). Separate switch from test apparatus.
(3). Locate pressure switch on engine fuel (f). Install new Oring and bushing on
pump filter (Ref. Figure 503, Figure 504 switch. Torque switch bushing.
or Figure 505). Disconnect bypass
(7). Bench test 369D28144 bypass pressure
switch wire knife splice.
switch as follows (denoted by six
housing screws):
CAUTION
(a). Assemble test equipment shown in
D Pressure switch is easily damaged. A Figure 502. Connect tester to pres-
slight shearing force applied to half the sure switch lead and connect ground
pressure switch can cause leakage and, or test lead to one of six screws on the
operational failure. Always grip both housing body.
halves of pressure switch hex flats with (b). Pressure Method:
wrench when loosening or torquing at-
taching hardware. 1). Remove bushing and Oring from
switch. Attach tubing to switch
D Bypass pressure switch is not field repair- port A as shown. Tubing has to be
able. Do not disassemble switch. Return airtight.
faulty switches to vender for repair.
2). Add pressure to the tube. Ohmme-
NOTE: For all torques in the following proce- ter must indicate switch contact
dures, refer to Figure 503, Figure 504 or closure as pressure passes between
Figure 505. 8 9 psig (16.3 18.3 in. hg.).
Page 506
Revision 19 280000
MAINTENANCE MANUAL
3). Hold pressure for five minutes and (e). Set battery switch to EXT PWR.
check for bleedoff. Any bleedoff
indicates a leak in the switch and (f). Reset INSTR circuit breaker.
requires switch replacement. (g). Set caution and warning light
4). Slowly release pressure. Ohmme- dimmer control on BRT.
ter must indicate switch contact (h). Test caution and warning light array.
opening by 4 psig (8.1 in. hg). Replace lamps as required.
(c). Vacuum Method: (i). Connect a jumper wire between
switch body and airframe ground
1). Remove bushing and Oring from E12.
switch. Attach tubing to switch
port B as shown. Tubing has to be (j). Set start pump switch; ON. FUEL
airtight. FILTER caution light should come
on. If FUEL FILTER caution light
2). Add vacuum to the tube. Ohmme- fails to light but works when tested,
ter must indicate switch contact switch is probably faulty. Replace
closure as vacuum passes between switch and repeat operational test.
8 9 psig (16.3 18.3 in. hg.).
(k). Check switch diaphragm for leakage
3). Hold vacuum for five minutes and through open port while pressurized.
check for bleedoff. Any bleedoff Replace a leaky switch.
indicates a leak in the switch and
requires switch replacement. (l). Disconnect jumper wire between
pressure switch and ground. Set start
4). Slowly release vacuum. Ohmmeter pump switch; OFF. Set battery
must indicate switch contact switch; OFF. Disconnect external
opening as vacuum reaches 4 psig power and battery.
(8.1 in. hg).
(m). Disconnect bypass hose from switch
(d). Separate switch from test apparatus. bushing. Install an airtight cap on
hose.
(e). Install new Oring and bushing on
switch. Torque switch bushing. (n). Remove plug from adapter fitting.
Install bypass switch assembly and a
(8). (Model 250C20B/R2 Series Engines) new Oring in adapter fitting. Torque
Perform a switch operational check as switch assembly.
follows:
(o). Remove plug from bypass hose.
(a). Uncap and attach bypass hose to Attach hose to switch bushing.
bushing. Torque hose nut. Torque hose nut.
(b). Install a suitable airtight plug and (p). Install insulating sleeve and connect
Oring in adapter fitting. switch wire knife splice.
(c). Connect and insulate switch wire (q). Bleed fuel system.
knife splice.
(r). Operate engine per Pilots Flight
(d). Have an assistant hold switch clear Manual and check fuel system for
of adjacent structures. Connect correct operation. Shut down engine.
battery and external electrical power. Inspect fuel system for leaks.
Page 507
280000 Revision 29
MAINTENANCE MANUAL
PRESSURE METHOD:
APPLY 89 PSIG (16.318.3 IN. HG.) TO CLOSE SWITCH.
BLEED OFF TO 4 PSIG (8.1 IN. HG.) TO OPEN SWITCH.
PORT A
NOTE 2
36 INCH
SCALE
3/8" TYGON TUBING

OHMMETER (OR EQUIV.) 36 IN.
OR
CONTINUITY TESTER
PORT B
VACUUM METHOD:
APPLY 89 PSIG (16.318.3 IN. HG.) TO CLOSE SWITCH. PORT A
BLEED OFF TO 4 PSIG (8.1 IN. HG.) TO OPEN SWITCH.
369D28144 FUEL FILTER NOTE 1

PRESSURE SWITCH
FUEL FILTER
PRESSURE SWITCH
OHMMETER
OR
CONTINUITY TESTER
PORT B
369H8144 FUEL FILTER

PRESSURE SWITCH
NOTES:
1. CONNECT GROUND TEST LEAD TO ONE OF
THREE SCREW HEADS ON THE HOUSING BODY.
2. CONNECT GROUND TEST LEAD TO ONE OF
SIX SCREW HEADS ON THE HOUSING BODY. G280010B
Figure 502. Fuel Filter Caution Light Pressure Switch Test (C20/C30 Engines)
Page 508
Revision 19 280000
MAINTENANCE MANUAL
ELBOW, TORQUE: 2025 IN. LB

(2.262.82 NM)
BEFORE FILTER
PORT (BF) REDUCER, TORQUE; 2025 IN. LB
(2.262.82 NM)
FITTING, TORQUE; 4050 IN. LB
(4.525.65 NM) ENGINE FUEL
PUMP FILTER
FUEL FILTER PRESSURE SWITCH,

TORQUE; 4050 IN. LB (4.525.65 NM)
BUSHING, TORQUE; 4050 IN. LB

(4.525.65 NM)
ELBOW, TORQUE; 2025 IN. LB

(2.262.82 NM)
HOSE
G280009A
Figure 503. Fuel Filter Caution Light Pressure Switch (C30 Engine)
ENGINE FUEL
PUMP FILTER AFTER FILTER
ORING
BEFORE FILTER PORT (AF)
PORT (BF)
REDUCER, TORQUE; 4050 IN. LB
(4.525.65 NM)
HOSE

(4.525.65 NM)
ORING

ELBOW, TORQUE; 2025 IN. LB TORQUE; 4050 IN. LB (4.525.65 NM)
(2.262.82 NM) (2 PLS)
ORING
(4.525.65 NM) G280008A
Figure 504. Fuel Filter Caution Light Pressure Switch (C20 Engines)
Page 509
280000 Revision 19
MAINTENANCE MANUAL
AFTER FILTER
PRESSURE TAP
BEFORE FILTER ORING

FUEL PUMP
PRESSURE TAP SEAL DRAIN
ORING (4.525.65 NM)
ORING
REDUCER, TORQUE; 4050 IN. LB
(4.525.65 NM)
TORQUE; 4050 IN. LB (4.525.65 NM)
TORQUE 2025 IN. LB
(2.262.82 NM) ORING
(4.525.65 NM)
TORQUE; 2025 IN. LB

(2.262.82 NM)
HOSE
G280027B
Figure 505. Fuel Filter Caution Light Pressure Switch (C20R/2 Engines with CECO Pump)
Page 510
Revision 19 280000
MAINTENANCE MANUAL
FUEL SYSTEM
INSPECTION/CHECK
WARNING Consumable Materials

D Avoid fuel vapor ignition and fire.
Item Nomenclature
Use only nonsparking tools and ex-
plosion proof work lights. Attach he- CM309 Lacquer, green
licopter to an approved electrical N/A Lockwire CRES
ground. Switch OFF all electrical
CM714 Tape, pressure sensitive
power. Disconnect external power
and battery before opening fuel sys-
tem. Ensure work area is adequately
ventilated. (1). Remove left instrument panel fairing.
Check for control cables marked (Jairen
D Air entering the airframe fuel supply Inc. 16722 PN 11026215N) with a date
lines may cause a power reduction or of (5/18) or later, and having a swage
flameout. Fuel system vacuum leak less than 0.50 inch (12.70 mm) in
check and fuel air bleed procedures length. These cables are MDHS part
must be performed after opening fuel numbers 369A8137503 and 603.
the supply system for any reason,
prior to releasing helicopter for (a). Inspect cable casing for a green
flight. stripe. The green stripe indicates
that cable has been previously pull
1. Fuel System General Inspection tested.
(1). Remove right and left fuel tank floor
access panels. (2). Unpainted control cables, P/N
369A8137503 and 603 fitting the
(2). Inspect fuselage bottom skin for preceding description require a manda-
evidence of fuel leakage. No leaks tory 50 pound (222.4 N) pull test to
allowed. Determine source and repair determine cable swage integrity.
as required.
(a). Unclamp cable from canopy or
(3). Inspect fuel lines, fittings, cell access instrument panel support structure
covers, fuel quantity unit, clamps and (Ref. Figure 401).
attaching hardware for leakage,
corrosion and security. Inspect fire (b). Behind instrument panel; back cable
sleeves for cuts, tears and punctures. retaining nut completely off threaded
No leakage allowed. Repair or replace portion of casing.
components as required.
(4). Inspect electrical wiring and connectors (c). Wrap a 12 inch (30.48 cm) length of
for corrosion and security. Replace or two inch 5.08 cm) wide duct tape or
repair wiring as required. equivalent around cable casing about
0.50 inch (12.70 mm) behind casing
(5). If start pump wire is tyrapped to start swage or instrument panel, whichev-
pump line, inspect security and condi- er is furthest from front of instru-
tion of tyraps. ment panel.
2. Fuel Shutoff Valve Control Cable Swage (d). Wrap one end of 0.042 lockwire
Test (369D/E) around cable and attach the other
end to the spring scale (Ref.
(Ref. Figure 601) Figure 601).
Page 601
280000 Revision 19
20
19
MAINTENANCE MANUAL
INSTRUMENT PANEL
CLAMP
FRONT OF INSTRUMENT
CABLE CASING PANEL
NOTCHED WASHER
TAPE LOCKWIRE
SWAGE
0.265 INCH (6.731 MM)
THREADS
FLANGE
NUT
NOTCHED WASHER TO SLIP
OVER CABLE CASING
BACK OF INSTRUMENT
PANEL
G280011B
Figure 601. Fuel ShutOff Control Cable, PN 369A8137503 Pull Test
Page 602
Revision 19 280000
MAINTENANCE MANUAL
(e). Notch a 0.265 ID x 0.063 inch (6.73 (5). Ensure shutoff valve control knob is
ID x 1.60 mm) thick washer and pushed in. Valve ball must be wide
position over cable between tape and open.
back of instrument panel. (6). Pull control knob out to stop. Valve ball
Sudden cable separation should be closed.
WARNING may cause serious personal (7). Valves that can not be fully closed or
injury. Be properly braced while pull- opened must be overhauled or replaced
ing on the cable. prior to further flight.
(f). Apply a steady tension through the (8). Disconnect control cable from valve.
spring scale up to 50 pounds (222.4 (9). Inspect shutoff valve lever and cable
N). Relax the tension. swivel hardware for corrosion and wear.
Check lever for smooth movement from
(g). Inspect cable casing swage for
closed to open stops.
separation.
(10). Use a spring scale to check tension
(h). Replace separated/unserviceable required to move valve lever from full
cable assemblies. open to closed. Design force require-
ment is 1.5 3.5 pounds (6.7 15.6 N)
(i). If the swage held without apparent maximum.
damage, paint a green lacquer
(CM309) stripe around the swage/ (11). Inspect valve for evidence of external
casing joint. leakage. External leakage not allowed.
(12). Check that lever detents at open and
(3). Install and secure cable hardware.
closed positions. Repair or replace valve
(4). Perform the following inspections and as required.
checks on all model helicopters. (13). Connect and rig valve control cable.
Install cotter pin on cable swivel.
(a). Remove left fuel cell floor access
panel. 4. Fuel Quantity Transmitter Inspection
(b). Inspect fuel shutoff cable, nylon (1). Remove left fuel cell floor access panel.
grommets and attaching hardware (2). Check 369D helicopters for potting
for condition and security. compound on top of transmitter. Apply
missing potting compound per repair
(c). Operate cable and check for binding. instructions. Check transmitter
Cable bend radius to be 3.5 inches, electrical terminals and wire harness
minimum. where exposed for security and condi-
(d). Push knob in and check for 0.090 tion.
0.150 inch (2.286 3.81 mm) gap (3). Where potting compound has been
between bottom of plunger and top of installed, use a pointed probe and
plunger housing (Ref. Figure 401). bright light to inspect interface between
potting compound and flange plate for
3. Fuel Shutoff Valve Inspection voids, debonding and separations.
Inspect area around terminal fasteners
(1). Shut down and disconnect all electrical for voids. No separations or voids are
power. allowed.
(2). In cargo/passenger compartment, open (4). Remove and test unit as required.
left fuel cell access panel.
(5). Repair or replace potting compound.
(3). Disconnect fuel supply tube from fuel 5. Tank Vent System Inspection
shutoff valve.
(1). Remove controls access door. Discon-
(4). Use an inspection mirror and flashlight nect hoses from forward and aft vent
to check shutoff valve ball position. crossover tubes.
Page 603
280000 Revision 19
MAINTENANCE MANUAL
(2). Blow lowpressure compressed air

through vent system to verify passages Special Tools
are clear. (Ref. Section 910000)
Item Nomenclature
(3). Check vent fairing passages for obstruc- ST801 Hand operated vacuum pump kit
tions and condition. Repair or replace
fairings as required.
Air entering the airframe
WARNING fuel supply lines may cause
(4). Inspect vent system hoses for deteriora- a power reduction or flameout. Fuel
tion. Pinch or bend hoses and look for system vacuum leak check and fuel air
surface cracks. Replace hose if cracks bleed procedures must be performed
are apparent. after opening the fuel supply system
for any reason, prior to releasing heli-
(5). Inspect vent tubes for dents, cracks, copter for flight.
deformation or corrosion. Smooth
nonrestrictive dents are permissible (1). Remove left fuel cell floor access panel.
except at lower end which must fit flush (2). Pull FUEL shutoff valve knob out to
within vent fairing flared riser. stop. Verify that fuel shutoff valve lever
is hard against its OFF stop.
(6). Inspect crossover fittings for cracks,
dents or corrosion. Smooth nonrestric- (3). In engine compartment; remove the
tive dents are permissible. upper drain plug from the fuel pump
filter bowl.
(7). Check that forward crossover antisi- (4). On C30 and C20R installations, remove
phon holes are open and clean. and plug the fuel vapor return line.
(8). With vent tube removed inspect vent (5). Assemble vacuum pump (ST801) hoses,
tube emergency shutoff valve for filter port adapter, shutoff valve and
condition. Valve should remain open vacuum gauge.
when held vertical. Valve should be (6). Install the vacuum gauge in the line
closed when held in the 45 from between the filter port adapter and
vertical position. While held in the 45 shutoff valve. Attach the vacuum pump
position, blow in the valve assembly above the shutoff valve.
and check that valve is closed (Do not
use compressed air). Valve shall open (7). Attach vacuum test vacuum pump to
when returned to the 25 position. engine fuel filter upper drain port.
Replace obstructed valve assembly. Apply 8.0 Hg vacuum. Close vacuum
line shutoff valve.
6. Fuel System Vacuum Leak Inspection (8). Fuel system shall hold vacuum between
8.0 and 7.5 Hg for two minutes.
Fuel is drawn out of the tank by the engine
driven fuel pump when the START PUMP is NOTE: Vacuum loss exceeding 0.5 Hg in two
switched OFF on Model 250C20 Series minutes indicates a leak in the system be-
engine installations and at all times in Model tween, and including, the fuel shutoff valve
250C30 engine installations. Water, ice, dirt, and engine.
fungus or a few pinhole leaks in the supply (9). If test is satisfactory, remove test
system between the fuel tank sump pickup and vacuum. Inspect and replace filter plug
engine driven fuel pump may cause power Oring as required. Install filter plug.
surges, deceleration and, or flameout. A
vacuum leak inspection will determine (10). On C30 and C20R installations,
whether or not air is being drawn into the reconnect and torque the fuel vapor
engine fuel supply system. return line.
Page 604
Revision 28 280000
MAINTENANCE MANUAL
(11). Retorque fuel line connections (Ref. 9. Fuel Cell Inspection

Table 401) and where installed, antiice
(airframe) fuel filter fittings and line CAUTION
nuts (Ref. Sec. 282500). Repeat
vacuum test. D Do not work on Uniroyal fuel cell in ambi-
ent temperatures below 50F (10C).
(12). If system continues to leak, disconnect
and install airtight caps on lines and D Do not work on Engineering Fabric Corp.
fitting ports in a progressive sequence fuel cell in ambient temperatures below
from fuel shutoff valve toward engine. 70F (21C).
The fuel shutoff and drain valve D Do not remove fuel cells unless absolutely
installations should be especially required.
suspect. Apply vacuum at each stage D The barrier can be invisibly torn, punc-
until leak has been isolated. Replace tured or cracked by careless handling.
parts as required.
D Do not carry or move cell by its metal fit-
NOTE: If the vacuum held at 7.5 Hg or better, tings.
airframe system seal is satisfactory and D Never probe cell material with sharp
leak is due to an engine fuel system prob- edged or pointed tools.
lem. Refer to the applicable Allison and Ben-
dix manuals for additional information. NOTE:
(13). Apply a torque stripe to all effected fuel D Nonselfsealing and selfsealing cells
line fittings and nuts. are primarily a 0.002 inch (0.051 mm)
thick nylon barrier membrane sand-
7. Start Pump Operational Check (Model wiched between lightweight construc-
250C20 Series Engines or 250C30 Engine tions of either rubberized (Uniroyal) or
With Optional Maintenance Fuel Pump) plasticized (Engineered Fabrics Corp.)
nylon fabric that protects and strength-
(1). Remove fuel cell floor access panels. ens the barrier.
Do not operate start pump in an D Selfsealing cells may have one or more
CAUTION empty fuel tank. thin layers of natural rubber sandwiched
between the barrier and fabric plies.
(2). Refuel helicopter.
(1). Apply protective tape to all machined
(3). Connect battery and external power. metal fittings.
(4). Set battery switch to EXT PWR. (2). Perform cell inspection on a padded,
clean, craft paper covered surface.
(5). Push FUEL shutoff valve knob in to
open shutoff valve. (3). Inspect fuel cells per applicable man-
ufacturers requirements.
(6). Set START PUMP switch ON to
pressurize fuel system. 10. Fuel Cell Leak Inspection
(7). Inspect all line connections for leaks.
(8). Shut down start pump. (Ref. Section 910000)
Item Nomenclature
(a). Repair leaks as required. N/A Ammonia
8. Drain Valve Inspection N/A Cloth, cotton flannel
N/A Phenolphthalein, crystalline
(1). Inspect tank sump drain valve for CM218 Alcohol, denatured
leakage and security. No leakage
CM810 Leak detector, liquid
allowed.
CM820 Cheesecloth
(2). Replace valve as required.
Page 605
280000 TR10002
MAINTENANCE MANUAL
Any one of three techniques can be used to find B. Phenolphthalein Stain Inspection
leaks in nonselfsealing and selfsealing fuel Procedures
cells. The methods are listed in ascending
order of effectiveness and complexity in terms (1). Remove cell from helicopter.
of required equipment, materials, time, and
(2). Lay cell out on a padded table. Install
effort.
all but one of the cell closures.
Soap bubble leak inspection. (3). Make phenolphthalein solution as
Phenolphthalein stain inspection. follows:
(a). Add 40 grams phenolphthalein
Liquid stand inspection.
crystals to 1/2 gallon (1.9 L) of
NOTE: The soap bubble and phenolphthalein denatured alcohol (CM218) and stir.
inspections require the cell to be inflated (b). Add 1/2 gallon (1.9 L) of water. Allow
with air. to stand 30 minutes. Stir before
(1). Manufacture or supply the following using.
equipment necessary to do soap bubble (4). Pour commercial ammonia on an
or phenolphthalein inspections: absorbent cloth in a ratio of one
(a). Rigid, airtight closures or plugs to teaspoon (3 ml) per cubic foot of cell
seal all cell openings. Fit one cover capacity (minimum of 10 ml or 3.3
plate with: teaspoons).
(a). Place the ammonia saturated cloth
(b). An air pressurization inlet fitting.
inside the cell and install the remain-
(c). A manometer or an extremely ing cover.
accurate and sensitive low pressure (b). Inflate cell with air to 1/4 psi (1.7
air gauge. kPa) maximum. Maintain 1/4 psi (1.7
A. Soap Bubble Leak Test Procedures kPa) pressure for 15 minutes mini-
mum, before proceeding.
NOTE: Soap bubble test reliability is good for
(c). Soak a large white cloth in the
bladder type nonselfsealing cells.
phenolphthalein solution. Thoroughly
(1). Remove cell from helicopter. wring cloth out.
(2). Lay cell out on a padded table. Install (d). Spread and smooth cloth onto cell. Do
cell closures. not let cloth dry out.
(3). Inflate cell to 1/4 psi (1.7 kPa), maxi- (e). A red spot will appear on the cloth
mum. where there is a leak in the cell wall.
Mark each leak.
(4). Unless leak is immediately evident,
(f). Inspect the entire exterior surface of
maintain 1/4 psi (1.7 kPa) pressure for
the cell.
two hours to allow any air trapped in
cell exterior laps and seams to escape. (5). Repair cell as required.
(5). Run soap solution around all patches, C. Liquid Stand Inspection
lap joints, seams, fittings, creases,
abrasions and any other suspicious NOTE:
areas. Bubbles will appear over a leak. D Engineered Fabrics Corp. recommends
VITHANE\R cells be supported in a fix-
(6). Mark leak areas with a white or yellow ture for the liquid stand inspection.
crayon.
D Uniroyal rubberized fabric cells do not re-
(7). Repair cell as required. quire support for this test.
Page 606
Revision 19 280000
MAINTENANCE MANUAL
(1). Remove cell from helicopter and place

on a clean, padded, kraft paper covered Special Tools
table. (Ref. Section 910000)
Item Nomenclature
(2). Fabricate closure plates for each cell N/A Manometer
opening as follows:
(a). The object is to completely fill the cell (1). Plug vent system.
and eliminate all air pockets.
(2). Remove left and right cell floor access
panels.
(b). Equip one of the plates with liquid
filler and vent stand pipes at least six (3). Install manometer and air pressuriza-
inches (15 cm) tall. tion equipment.
(3). Fill the cell with Stoddard solvent, (4). Apply 2 psi (14 kPa) air pressure for 10
Stanisol or Varsoline. minutes to precondition cells. This
forces trapped air from between fuel
(4). Permit cell to stand undisturbed for 24 cells and helicopter structure. If
hours. necessary, repeat until cells adjust to
contour of cell bay.
(5). Inspect paper to determine where cell is
leaking. (5). Apply 2 psi (14 kPa) air pressure for 15
minutes with no visible, less than 1/4
(6). Change paper as required. Drain, turn inch (6.35 mm) drop on manometer.
over, refill and let cell stand for another NOTE: If pressure drop occurs, check all vent
24 hours to ensure liquid has contacted plugs, fittings and retest cells.
all cell surfaces.
(6). Repair or replace parts as necessary to
(7). Repair cell as required. eliminate pressure drop.
(7). Unplug vent system. Remove manome-
11. Fuel Tank Pressure Leak Test ter and pressurization equipment.
Check installed fuel tanks and plumbing for (8). Install left and right cell floor access
leaks as follows: panels.

280000 Revision 19
MAINTENANCE MANUAL
FUEL SYSTEM
REPAIRS
1. Fuel Shutoff Valve Control Cable Repair (a). Only personnel specifically trained to
inspect and repair the fuel cells
installed in 369/500 series helicopters
perform the work.
Item Nomenclature (b). Customers planning to do their own
CM118 Grease fuel cell repairs order manuals from
the applicable cell manufacturer
before beginning repair tasks (Ref.
NOTE: Worn fuel shutoff valve control cables Sec. 010000).
are normally replaced as an assembly.
(c). Cell inspections, maintenance and
(1). The only authorized repair is replace- repair be only per the cell manufac-
ment of a missing detent ball, as turers advice and instructions.
follows:
(2). Bladder or self sealing fuel cells are
(a). Disconnect cable from fuel shutoff supplied to MDHS by Uniroyal, Inc.,
valve lever swivel. and Engineered Fabrics Corporation.
(b). Pull plunger out until detent ball Engineered Fabrics Corp., and
hole is visible. Insert detent release CAUTION Uniroyal fuel cell construction
rod in plunger. Align notch in detent materials, inspection requirements, repair
release rod with plunger detent ball methods and requirements, supplies and
hole. materials are not compatible or inter-
changeable.
(c). Apply grease (CM118) between
plunger and plunger housing. (3). Cells manufactured by Uniroyal are an
assembly of nitrile rubber impregnated
(d). Insert detent ball in plunger hole. woven nylon inner and outer coverings
Push release rod and plunger to full with an impervious 0.002 inch (0.051
open position. mm) thick, nylon barrier membrane
sandwiched between the coverings.
(e). Rig fuel shutoff valve cable.
(4). Fuel cells produced by Engineered
2. Fuel Shutoff Valve Repair Fabrics Corp. are constructed of
VITHANE/R polyurethane plastic
(1). Overhaul Dukes Inc. valves with repair
impregnated fabric.
kit, part No. 15951000. No other
repairs are authorized. 4. Uniroyal SelfSealing and
(2). Electric pencil the letter M at the end of NonSelfSealing Cell Repairs
the part number, i.e., 369A81045M. Procedures in this section cover Uniroyal
selfsealing and nonselfsealing fuel cell
3. Fuel Cell Repair repairs as follows:
(1). MDHS cannot guarantee the currency, D Scuff Mark Repairs.
completeness or technical accuracy of
fuel cell repair procedures provided D Reinforcements, Hangers and Splice
herein. Since cell repair materials, Repairs.
techniques, and procedures may be
changed or deleted by the cell manufac- D Loose Patch Repair.
turers without notice to MDHS light D Patch Installation.
helicopter publications; we strongly
recommend that: D Loose Edges and Lap Seam Repair.
Page 801
280000 Revision 19
MAINTENANCE MANUAL
D Blister Repairs. A. Scuff Mark Repair

(1). Fabric exposed by a scuff mark may be
Fuel cells are fragile. Do not at- buffed, cleaned, coated with cement and
CAUTION tempt to fold/unfold or handle
allowed to airdry for 8 hours.
cells in temperatures below 50F (10C).
Cell material is easily cut, torn or punc- (2). No patch is required unless fabric is
tured. Never use sharp edged or pointed torn.
tools to probe damage or to puncture blis- (3). Install patches where required (Ref.
ters. Puncturing the 0.002 inch (0.051 mm) Patch Installation).
thick nylon fuel barrier of a nonselfseal-
ing cell will cause the cell to leak. Punctur- B. Reinforcements, Hangers and Splice
ing the nylon barrier of a selfsealing cell Repairs
will allow fuel to activate the rubber sealing
(1). Loose reinforcement edges, hangers or
agent that will swell over time and possibly
lap splices must be lifted, buffed,
rupture the cell. In any case, cells with acti-
cleaned, cemented and cured under
vated seal compound are not repairable.
pressure per applicable instructions
Barrier membrane can be invisibly torn by
provided (Ref. Patch Installation).
rough handling or impact. Handle cells with
care and no more than necessary. Protect C. Loose Patch Repair
metal fittings from damage.
(1). Replace loose patches with new patch
installations (Ref. Patch Installation).
NOTE: Accomplish fuel cell repair work in tem-
peratures ranging from 60 80F (16 (2). Where two opposing patches have been
27C) and in less than 50% humidity. installed over cell wall damage, unless
otherwise indicated by inspection,
replace only the loose patch.
(Ref. Section 910000) D. Patch Installation
Item Nomenclature (1). Drain, remove and thoroughly dry cell
N/A Polyethylene plastic, sheet or roll as soon as possible after determining
cell repair is required. Drying time may
CM211 Solvent be accelerated by keeping cell at 80F
CM219 Methylethylketone (27C) and ventilating interior with dry,
CM603 Patching material low pressure air.
CM604 Patching material (2). Inspect fuel cell.
CM605 Fuel cell repair kit
CAUTION
CM607 Cement
CM608 Cement D Do not repair tears or holes over two in-
CM609 Repair kit
ches long using cold patch repair. Do not
attempt to repair bonded fittings or cor-
CM804 Emery cloth, fine ners. Contact Uniroyal, Inc. when corner
CM820 Cheesecloth or fitting damage is discovered or when
cell wall damage exceeds two inch (5.08
cm) length limit.
Special Tools
(Ref. Section 910000) D Never expose a dry cell to high tempera-
Item Nomenclature tures and, or direct sunlight for long peri-
ods of time. If repairs will not be started
N/A CClamp, 8 12 inch within ten days, prepare cell for storage.
N/A Patch pressure plates, 1/2 inch thick
NOTE: Damp air, especially in combination
aluminum stock
with low temperatures, will cause water to
N/A Brayer condense on cement applications. Water in-
hibits patch adhesion.
Page 802
Revision 19 280000
MAINTENANCE MANUAL
(3). Both sides of a cell must be patched to (12). Continue to wipe cell and patch,
repair any one hole or tear. changing cheesecloth and applying
clean solvent as required, until no stain
(4). Thoroughly clean cell internal and or particles appear on cheesecloth pad
external repair areas with cheese cloth after the last wipe.
(CM820) dampened with solvent
(CM211) or MEK (CM219). Use cement sparingly. Two,
CAUTION thin, even coats provide better
(5). Collapse cell and expose external adhesion than one thick coat.
damage area on a clean, flat working
(13). Position a sheet of polyethylene plastic
surface.
beneath cell damage to keep cement off
(6). Use a greaseless silver pencil to outline opposite cell wall.
patch installation area two inches NOTE: Determine cement adhesive tack with a
beyond damage in all directions. test specimen. Apply cement to a piece of
(7). Handbuff an area 1/2 inch (12.7 mm) buffed, scrap patch material each time ce-
larger than space occupied by patch ment is spread on cell and repair patch.
with fine emery cloth (CM804) to (14). Coat patch, test specimen, and fuel cell,
provide a roughened substrate for including edges of damage, with EC678
cement application. Do not cut through cement (CM607) or Uniroyal #3230
cell fabric. cement (CM608). Allow cement to dry
15 minutes before application of a
(8). Select a patch (CM604) of #5218 second coat. Allow second coat to dry 15
material for nonselfsealing cell minutes.
exterior, or Uniroyal #5241/5241
sandwich material for selfsealing cells. (15). Press a bare knuckle into cement on
Trim patch to extend two inches (5.08 test specimen. Cement that tears away
cm) beyond edges and ends of damage from skin leaving a rough, finely
in all directions. Tilt scissors to bevel peaked imprint without transferring to
patch edges away from cell surface. knuckle, is ready for patch installation.
Radius all patch corners. (16). Wipe cement with cheesecloth moist-
(9). Handbuff patch gummed surface with ened with solvent to reactivate adhesive
fine emery cloth. Ensure entire patch when required.
joint surface has been abraded. NOTE: A brayer or similar tool is required to
systematically roll patch into contact with
(10). Repeat buffing procedures on cell cell. Apply patch as follows:
interior surface. Buff internal patch
(CM603) trimmed from Uniroyal (17). Center patch on repair area. Stick one
#5200/5187/5194 sandwich material. edge down and double check patch
alignment. If required, release adhesive
Fuel cell and patch contact sur- by flooding joint with solvent. Check
CAUTION faces must be perfectly clean adhesive tack again before proceeding
and dry prior to adhesive and patch applica- with patch installation.
tion. Rubber and fabric particles, moisture,
and fuel or oil from fingers will prevent NOTE: The object of the next step is to get the
proper patch/cell adhesive cure and may patch down without trapping any air under
subsequently provide a leak path. Wear it.
clean, lint free gloves to handle patch and (18). Hold free edge of patch off cell. Follow
cell after preparing surfaces for cement and one line and roll tool back and forth
patch application. over patch. Advance toward loose end,
1/4 inch (6.35 mm) per pass until patch
(11). Install exterior patch first. Wipe cell
is down and free of trapped air.
exterior and patch faying surfaces with
clean cheesecloth dampened with (19). An alternate technique is to lay
Uniroyal #3339 solvent or MEK. prepared patch on a perfectly clean
Page 803
280000 Revision 19
MAINTENANCE MANUAL
sheet of polyethylene plastic about E. Loose Edge and Lap Seam Repairs
twice the size of the patch. Locate
Loose lap seams should be re-
plastic sheet and patch over cell repair CAUTION paired as soon as possible after
area; then, slip sheet from under patch
discovery.
as patch is rolled down, 1/4 inch (6.35
mm) at a time. NOTE: Loose lap seam edges not more than two
inches long on cell interior or exterior sur-
(20). Fabricate two smooth, flat, rigid, metal faces may be repaired. Contact Uniroyal,
plates with no sharp edges or corners. Inc. for repair data addressing lap seam sep-
Plates must be larger than cemented arations exceeding two inch (5.08 cm) length
repair area. limit. Seam separation repairs require buff-
ing, cementing and a patch installation.
Excessive clamp pressure may (1). Lift seam separation and buff flap and
CAUTION deform cell and, or squeeze ce- cell faying surfaces with emery cloth
ment out of joint. (CM804).
(2). Buff an area on exterior surface
(21). Cover both sides of repair with sheet extending 2 inch (5.08 cm) in all
polyethylene plastic or oiled paper large directions from seam separation.
enough to cover entire cemented area.
CAUTION
NOTE: Do not include opposite cell wall in
clamp up. Work through cell access opening D Fuel cell and patch contact surfaces must
and arrange cell as necessary to clamp only be perfectly clean and dry prior to adhe-
the wall with the patch installation. sive and patch application. Rubber and
fabric particles, moisture, and fuel or oil
from fingers will prevent proper patch/
(22). Sandwich repair area and barrier cell adhesive seal and may subsequently
material between pressure plates. provide a leak path. Wear clean, lint free
Install at least two Cclamps over gloves to handle patch and cell after pre-
pressure plates. Equalize clamp paring surfaces for cement and patch
pressure. application.
D Careless application of compressed air be-
(23). Do not disturb cell. Maintain pressure tween lap joints may separate seam fur-
for six hours, minimum, after which cell ther.
is ready for internal patch installation.
(3). Either airvacuum or blow buffing dust
(24). Remove clamps and plates. out of separation with dry, low pressure
compressed air.
(25). Clean patch and cell internal repair (4). Wipe inside and outside of repair area
area with solvent or MEK saturated clean with cheesecloth (CM820)
cheesecloth swabs. moistened with solvent (CM211) or
MEK (CM219). Continue wiping with
(26). Apply two coats of cement, allowing 15 fresh solvent dampened cheesecloth as
minutes drying time between coats. required until no stain or particle
Allow 15 minutes for second coat to set. appears on the swab after the last wipe.
Allow area to dry.
(27). Install and roll out patch. Use cement sparingly. Two,
adhesion than one thick coat.
(28). Position a barrier sheet under each
pressure plate. Clamp and cure instal- NOTE: Determine cement adhesive tack with a
lation for a minimum of 24 hours at 60 test specimen. Apply cement to a piece of
80F (16 27C) before leak testing buffed, scrap patch material each time ce-
and returning cell to service. ment is spread on cell and repair patch.
Page 804
Revision 19 280000
MAINTENANCE MANUAL
(5). Apply two coats of EC678 cement (15). Prepare cell wall and patch for installa-
(CM607) or Uniroyal #3230 (CM608) tion (Ref. Patch Installation). Install
allowing 15 minutes between applica- patch.
tions. Allow second coat to dry 15
minutes. F. Blister Repair
(1). Blisters can occur on cell interior and
(6). Roll separation together starting from exterior surfaces. blisters are caused by
the bottom of the pocket toward the a separation of the cell laminates and
open end, 1/4 inch (6.35 mm) per pass. may contain air or a combination of air
Ensure no air is trapped underneath. and fuel.
(7). Cover repair with a sheet of polyethyl- NOTE: Exterior blisters that contain fuel indi-
ene plastic or oiled paper large enough cate that the barrier has been penetrated.
to cover entire cemented area. Contact Uniroyal for repair information be-
fore proceeding. Blisters inside cell measur-
(8). Fabricate two smooth, flat, rigid, metal ing under one inch (2.54 cm) diameter are
plates with no sharp edges or corners. acceptable and need not be disturbed.
Plates must be larger than cemented (2). Buff surface of blister and area extend-
repair area. ing two inch (5.08 cm) in all directions
from its edge.
Excessive clamp pressure may
CAUTION deform cell and, or squeeze ce- Avoid damaging nylon barrier
ment out of joint. CAUTION membrane. Do not probe, cut, or
puncture blisters with tool perpendicular to
(9). Cover both sides of repair with polyeth- cell wall.
ylene plastic or oiled paper sheets large
enough to cover entire cemented area. (3). Slit blister open with an X cut to expose
all of the delaminated surface. Lift flaps
NOTE: Do not include opposite cell wall in and mop interior with clean cheesecloth
clamp up. Work through cell access opening (CM820) and solvent (CM211) or MEK
and arrange cell as necessary to clamp only (CM219). Buff underlying cell surface
the wall containing the seam repair. and blister flaps with emery cloth
(CM804). Airvacuum or blow away all
(10). Sandwich cell wall repair area and traces of buffing dust.
barrier material between pressure (4). Wipe inside and outside of repair area
plates. Install at least two Cclamps clean with cheesecloth moistened with
over pressure plates. Equalize clamp solvent or MEK. Continue wiping with
pressure. fresh solvent dampened cheesecloth as
required until no stain or particle
(11). Do not disturb cell. Maintain pressure appears on the swab after the last wipe.
for six hours, minimum, after which cell Allow area to dry.
is ready for patch installation.
Use cement sparingly. Two,
(12). Remove clamps and plates.
(13). Use Uniroyal #5200/5187/5194 sand- NOTE: Determine cement adhesive tack with a
wich patch material (CM603) on test specimen. Apply cement to a piece of
nonselfsealing and selfsealing cell buffed, scrap patch material each time ce-
interiors. ment is spread on cell and repair patch.
(14). Use Uniroyal #5241/5241 sandwich (5). Apply two coats of EC678 cement
patch material (CM604) on selfsealing (CM607) or Uniroyal #3230 (CM608)
cell exterior surfaces or Uniroyal #5218 allowing 15 minutes between applica-
patch material on nonselfsealing cell tions. Allow second coat to dry 15
exterior surfaces. minutes.
Page 805
280000 Revision 19
MAINTENANCE MANUAL
(6). Roll blister together starting from the 5. Fuel Quantity Transmitter Repair
bottom of each flap pocket toward the
open end, 1/4 inch (6.35 mm) per pass. Consumable Materials
Ensure no air is trapped underneath. (Ref. Section 910000)
Item Nomenclature
(7). Fabricate two smooth, flat, rigid, metal CM220 Naphtha aliphatic
plates with no sharp edges or corners. CM425 Sealing compound
Plates must be larger than cemented CM815 Solder
repair area.
Special Tools
CAUTION deform cell and, or squeeze ce-
Item Nomenclature
ment out of joint. N/A Solder gun
A. Resistor installation, Transmitters

(8). Cover both sides of repair with polyeth-
PN 369D296303, 369D296303701 and
ylene plastic or oiled paper sheets large
369A4245
enough to cover entire cemented area.
(1). Remove transmitter from helicopter.
NOTE: Do not include opposite cell wall in (2). Remove potting compound from top of
clamp up. Work through cell access opening transmitter to expose terminals and
and arrange cell as necessary to clamp only circuit board.
the wall containing the blister repair.
(3). Solder resistor to transmitter circuit
with tin alloy solder (Ref. Figure 501).
(9). Sandwich cell wall repair area and (4). Perform FUEL LEVEL LOW Caution
barrier material between pressure Light System Test and Fuel Quantity
plates. Install at least two Cclamps Transmitter Calibration and Adjust-
over pressure plates. Equalize clamp ment procedures.
pressure.
Naptha is a fire hazard. Per-
WARNING form work in a well venti-
(10). Do not disturb cell. Maintain pressure lated area away from potential sources
for six hours, minimum, after which cell of ignition.
is ready for patch installation; remove
clamps and plates. NOTE: All transmitters with exposed wire ter-
minals and, or circuit boards must be sealed
(potted) before they can be returned to ser-
(11). Use #5200/5187/5194 sandwich patch vice.
material (CM603) on nonselfsealing
(5). Remove all grime and oily residue from
and selfsealing cell interiors.
sealing compound application area with
naptha (CM220) and a soft bristle
(12). Use Uniroyal #5241/5241 sandwich brush. Blow away excess solvent with
patch material (CM604) on selfsealing dry low pressure compressed air.
cell exterior surfaces or Uniroyal #5218 (6). Ensure transmitter terminal connec-
patch material (51) on nonselfsealing tions are clean, tight, free of corrosion
cell exterior surfaces. and dry.
(7). Heat soak transmitter assembly in an
(13). Prepare cell wall and patch for installa- oven set at 100F (38C), maximum for
tion per instructions (Ref. Patch one hour to vaporize trapped volatiles.
Installation). Install patch. A heat gun may be used as an alternate
Page 806
Revision 19 280000
MAINTENANCE MANUAL
drying method. Pot transmitter electri- pound components per manufacturers

cal connections with sealing compound instructions.
(CM425).
(2). Apply to top of transmitter (Ref.
Figure 501).
B. MILS8802 Application
(3). Cure material per instructions before
(1). Combine MILS8802 sealing com- returning transmitter to service.

280000 Revision 19
MAINTENANCE MANUAL
Section
280060
Fuel System (600N)
MAINTENANCE MANUAL

MAINTENANCE MANUAL
FUEL SYSTEM
1. Engine Fuel System (8). A check valve attaches to the filler neck
fitting. The check valve located within
(1). Engine fuel system operational infor- the fuel cell. opens when the fuel cap is
mation is provided in the applicable removed by pulling a lanyard for
Allison Engine Operation and Mainte- refueling and defueling operations. The
nance Manuals (Ref. Sec. 010000). valve closes when the fuel cap is
secured to the filler neck fitting pre-
2. Fuel Cells venting fuel leakage.
(9). The leftrear cell cover supports the
(1). The MDHS helicopter standard fuel cell
manually actuated fuel shutoff valve,
consists of two interconnected crashre-
fuel supply hose, motive flow hose, fuel
sistant nonselfsealing bladder type
quantity probe wire harness and
cells having a total capacity of 116.2
attaching hardware.
U.S. gallons (439.9 Liter), with 114.6
U.S. gallons (433.8 Liter) usable. 3. Fuel Distribution
(2). Bladder crashresistant nonself (1). The fuel distribution system supplies
sealing fuel cells are supplied by fuel to the engine. The engine driven
Engineered Fabrics Corporation (Ref. fuel pump sucks fuel from the fuel cell.
Sec. 010000).
(2). Fuel is supplied from the fuel cell
(3). Cells are located in separate fiberglass through supply lines located under the
lined bays below the passenger com- passenger/cargo compartment floor and
partment floor. Both cells are supported within the fuel cell.
by a system of airframe brackets, (3). The ejector pump is driven by pressur-
hangers, grommets and nylon suspen- ized fuel (motive flow) returning from
sion cords. the engine driven fuel pump.
(4). Each fuel cell is equipped with two (4). The ejector pump scavenges fuel from
access covers, forward fuel vent aft fuel the forward portion of fuel cell and
vent forward vent crossover fittings and transfer fuel to the aft portion of the
fuel interconnect fittings. cell, thus motive flow.
(5). Each fuel cell contains two sump plates 4. Fuel Vent System
and two fuel drain valves
(1). Fuel cells are vented to the atmosphere
(6). Each fuel cell is divided by an internal through the bottom and side fuselage
lateral baffle which reduces fuel ports by a system of interconnected
sloshing during changes in flight hoses and tubes attached to the forward
attitudes. The baffles have openings inboard and aft inboard ends of each
across their face to allow fuel to pass fuel cell.
through them. This reduces the load on (2). The fuel vent float/rollover valves are
the baffles and provides even fuel located internally at each inboard
distribution within the cell. upper corner of the fuel cell. The vent
float/rollover valve allows the fuel cell
(7). Fuel tank servicing is through the cell to vent to the atmosphere during
filler neck on the right side of the aircraft fueling/defueling.
fuselage. The right side fuel cell
contains the gravity filler port, filler (3). Each vent float/rollover valve is
check valve, neck, cap and attachment designed so that when not submerged
hardware. in fuel and with airflow through the
Page 1
280060 Revision 19
MAINTENANCE MANUAL
valve between zero and the rated flow, the instrument panel face. The flexible
the valve remain open within 25 cable and housing is routed aft under
conical angle from vertical. the floor to the shutoff valve lever on
the left fuel cell access cover.
(4). The valve automatically closes when
the fuel level is at or above the float 7. Fuel Shutoff Valve
actuation level to prevent fuel loss
through the vent system. The valve will (1). The cable actuated, mechanically
also close with changes in aircraft detented fuel shutoff valve is located on
ground attitudes from 25 to 180 with the left fuel cell access cover. Valve
fuel present. lever arm travel from full open to closed
is 90.
(5). Flame arrestors located in the outlet
vent tube or standpipe prevents any 8. Fuel Filter Caution Light Pressure Switch
potential flames from reaching the vent
float/rollover valves and fuel cell. (1). A differential pressure switch is
installed across the engine fuel pump
filter pressure AF (after filter) and BF
5. Fuel Quantity System (before filter) ports just upstream of the
engine fuel pump. The switch is
(1). The fuel quantity system is powered by sensitive to a preset differential
24 28 Vdc current and consists of an pressure. An increase in BF pressure
electromechanical fuel quantity with a concurrent decrease in AF
indicator, a signal conditioner, two pressure due to partial or complete
capacitance type fuel quantity probes filter blockage may intermittently or
mounted in the left fuel cell, a float completely close the switch depending
switch located on the aft fuel quantity on the nature of the filtered material.
probes, a FUEL LEVEL LOW caution Switch contacts complete an electrical
light on the instrument console and circuit through a case ground that
interconnecting wire harness. switches on the FUEL FILTER
caution lamp, a part of the instrument
(2). The system is protected by a 5 ampere
console caution and warning light
circuit breaker. Power is supplied to the
array.
system from the DC bus, through a
circuit breaker. 9. Drain System and Drain Valves
(3). The float switch provides a electrical (1). Two spring loaded plunger tank sump
signal to the FUEL LEVEL LOW drain valve are installed in each cell
caution light panel located on the sump mount plate on the bottom of the
instrument panel. Refueling breaks the left and right fuel cell. The valve is
float switch circuit and switches off the accessed from under the helicopter.
FUEL LEVEL LOW caution lamp. The
switch is fixed to the aft fuel quantity 10. Fuel Supply Lines
probe and is not adjustable.
(1). The engine fuel supply lines consist of:
(4). Calibrating of the fuel system is
accomplished on the fuel quantity (a). A fuel inlet hose between the inlet
indicator calibration switch. By holding screen to the fuel shutoff valve.
the switch in the empty or full calibra-
tion positions a resistance is stored in (b). A engine feed hose between the fuel
the gauge memory circuit. shutoff valve and firewall fitting.
(c). A hose from the firewall fitting to the
6. Fuel Shutoff Valve Control engine filter inlet port.
(1). A red fuel shutoff control knob labeled (d). A return flow hose from engine to the
FUEL, PULL TO CLOSE is located on firewall fitting.
Page 2
Revision 19 280060
MAINTENANCE MANUAL
(e). A motive flow hose assembly between (g). A scavenge fuel cell hose from the
the firewall fitting and a flow check ejector pump to the bottom of aft cell
valve on the left aft cell cover. cover.
(f). A submerged motive flow hole from (h). Associated elbows, fittings and
aft cell cover to the ejector pump. unions.
Page 3/(4 blank)

280060 Revision 19
MAINTENANCE MANUAL
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Fault Isolation
Insufficient or no fuel to engine. Fuel tank empty. Refuel helicopter.
Disconnected or ruptured fuel line. Check all fuel lines for security and
condition. Repair or replace parts as
required.
Clogged fuel line. Repair as required.
Clogged fuel cell and start pump Clean as required.

inlet screens.
Twisted or kinked fuel supply hose. Repair as required.
Defective fuel shutoff valve. Repair or replace fuel shutoff valve.
Fuel shutoff valve control cable Repair or replace control cable.

failed or disconnected.
FUEL FILTER warning light on. Clogged engine fuel filters. Replace pump and gas producer fuel
control filters. Clean fuel control
pneumatic (air) circuits (refer to
Allison Engine Operation and
Maintenance Manual). When
installed, replace antiice (airframe)
filter (Ref. Sec. 282500). Bench
check FUEL FILTER caution light
pressure switch.
Fuel contamination. Inspect and clean the fuel cell and

start pump inlet screens if large
amounts of foreign material are
found in the engine driven fuel pump
filter (or the optional airframe fuel
filter if installed).
Defective fuel filter pressure switch. Replace pressure switch.
Wiring fault. Repair wiring.
Engine power surge or flameout. Water/ice in fuel system. Drain water out of tank and fuel
supply system.
Air in fuel system. Bleed fuel system.
Air leaking into system. Vacuum leak check fuel supply

system.
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280060 Revision 29
MAINTENANCE MANUAL
Table 101. Fuel Supply System Fault Isolation (Cont)

Bottom of fuselage stays wet with Loose or broken lines or fittings. Inspect and repair as required.
fuel.
Fuel cell leak. Remove, test and repair, or replace
cells.
Fuel cell interconnects leak Replace cell interconnect Orings.
FUEL LEVEL LOW caution light Defective aft fuel quantity probe Replace fuel quantity probe.
stays on, glows or flickers with low level switch.
known quantity above low level.
Erroneous fuel quantity gauge Loose or defective wiring or Inspect wiring and repair.
readings. connections.
Loose or incorrect wiring at the fuel Inspect wiring and repair.

quantity probes.
Defective gauge. Remove, test and replace a defective

gauge.
Defective forward or aft fuel Remove, test, calibrate and repair or

quantity probe. replace probe.
Page 102
Revision 19 280060
MAINTENANCE MANUAL
Table 102. Fuel Quantity System Wire Data List

Wire No. From Termination To Termination Specification
FQ1A22WHT J2511 HSD4123915 600N810771 87F5544 M2750022SP2T23
FQ1A22BLU J2512 HSD4123915 600N810772 87F5544 M2750022SP2T23
FQ2A22WHT J2513 HSD4123915 600N81077S 87F5547 M2750022SP2T23
FQ3A22WHT 600N81079S 87F5547 600N81077S 87F5547 M2750022SP3T23
FQ2A22BLU J2514 HSD4123915 600N81077R 87F5546 M2750022SP2T23
FQ3A22BLU 600N81079R 87F5546 600N81077R 87F5546 M2750022SP3T23
FQ2A22ORN J2515 HSD4123915 600N81077L 87F5548 M2750022SP2T23
FQ3A22ORN 600N81079L 87F5548 600N81077L 87F5548 M2750022SP3T23
JMPR J2516 HSD4123915 OUTER SHLD
FQ4A22N OUTER SHLD OVERBRAID 600N81077 NOTE M2750022SP2T23
FQ5A22N OUTER SHLD OVERBRAID 600N81079 NOTE M2750022SP2T23
JMPR J2512 SHLD HSD4123830 J2515 SHLD HDS4123915
JMPR J2515 SHLD HSD4123830 J2517 SHLD HDS4123817
JMPR P1A22 SHLD HSD4123830 P2A22 SHLD HDS4123817
J2518 SPARE
J2519 SPARE
J25110 SPARE
J25111 SPARE
J25112 SPARE
J25113 SPARE
NOTE: To 3 probe flange mount bolt.
OUTER
MS27474P10F35 SHIELD BRAID
P OUTER
SHIELD BRAID
J25
11 WHT
TO LOW LEVEL SWITCH TERM.. 1 (#4 LUG)
FQ1A2 BLU
2 2 TO LOW LEVEL SWITCH TERM.. 2 (#4 LUG)
WHT
3 TO PROBE TERM.. S (#8 LUG)
BLU AFT PROBE
4 FQ2A2 TO PROBE TERM.. R (#6 LUG)
ORN 2
5 TO PROBE TERM.. L (#10 LUG)
8
7
10 FQ4A2 TO AFT PROBE FLANGE MOUNTING BOLT
11 2
12 OUTER SHIELD
BRAID
13
ORN
6 TO PROBE TERM.. L (#10 LUG)
BLU
9 FQ3A2 TO PROBE TERM.. R (#6 LUG) FORWARD PROBE
2 WHT
TO PROBE TERM.. S (#8 LUG)
FQ5A2 TO FORWARD PROBE FLANGE MOUNTING BOLT

2
6G28020A
Figure 101. Fuel Quantity System Wiring Diagram

280060 Revision 21
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Cell Cleaning General (2). If a fuel cell that has previously
contained fuel is to be stored for longer
(1). Fuel cells are susceptible to fungus than three days, coat inside of cell with
growth after contact with contaminated a light coating of #10 weight, nonsyn-
fuel. Fungus trapped in the fuel filters thetic engine oil.
indicates fuel tank contamination.
Remove, inspect, clean or replace filter CAUTION
elements per applicable Allison Engine
Operation and Maintenance Manual. D Engineered Fabrics Corp. cells removed
Where installed, service antiice from service must not be left dry for more
(airframe) filter (Ref. Sec. 282500). than 3 days without the application of oil
as a plasticizing agent. The cell liner will
(2). Periodic incorporation of an FAA loose pliability if left dry for extended pe-
approved antifungal fuel additive will riods and subsequent flexing may cause
kill and prevent new fungus growth. the material to crack.
D Do not work on fuel cell in ambient tem-
2. Engineered Fabrics Corp. Fuel Cell peratures below 70F (21C).
Cleaning
(a). Fold cell over protective wadding as
Do not steam clean Engineered loosely as possible and with a mini-
CAUTION Fabrics Corp. fuel cells. Steam mum number of folds.
cleaning may cause irreparable damage.
(b). Wrap the cell in a protective cover.
(1). Clean cell exterior and interior surfaces (c). Put cell in a suitable storage/ship-
with warm soapy water and clean lint ping container. Use wadding as
free cloth. Rinse away all soap residue required to prevent movement. Do
and wipe dry. not stuff cell into an undersized
container.
3. Fuel Cell Handling, Storage and Shipping
(d). Store cell at 70F (21C) away from
Do not use cell fittings as hand sunlight and moisture.
CAUTION holds. Do not store fuel cells un-
5. Fuel System Air Bleed (Model 250C47
crated or exposed to direct sunlight, ozone,
Engine Installation)
dirt, moisture, solvents, chemicals, or ex-
tremes of heat and humidity. Fuel/air vapor discharged
WARNING during bleeding is a fire haz-
(1). Store and ship cells in a suitable ard. Prevent fuel vapor accumulation,
protective container. ignition and fire. Perform work in an
open, well ventilated area away from
(a). Apply protective tape over all cell all potential ignition sources. Attach
machined fittings. helicopter to an approved electrical
(b). Use packing material to keep the cell ground. Wear approved eye protection.
from shifting in transit. (1). Helicopters with C47 engines and
standard fuel supply systems are not
(c). Suspended selfsealing cells to equipped with a start pump.
maintain cell shape.
(2). Helicopters equipped with an airframe
4. Fuel Cell Preservation and Storage mounted fuel filter are equipped with
(Engineered Fabrics Corp. Cells) an airframe mounted fuel pump inside
the left fuel cell and can be primed
(1). Thoroughly clean cell with warm soapy using the same procedure as helicopters
water. Wipe completely dry. with the 250C20 Series engines.
Page 201
280060 Revision 32
MAINTENANCE MANUAL
(3). The standard helicopter fuel system (e). Open fuel shutoff valve.
only has an engine driven self priming
pump that will fill the fuel system when (f). Open throttle to ground idle position.
the engine is motored with the starter. (g). Squeeze primer bulb until fuel comes
Motor engine per the appropriate Pilots out of fuel line.
Flight Manual.
NOTE: When reinstalling fuel lines, refer to ap-
(4). Bleed air out of helicopter engine fuel propriate RollsRoyce Operation and Main-
controls per RollsRoyce Engine tenance Manual for proper torques.
(h). Remove primer bulb assembly from
(5). If fuel system fails to bleed properly, fuel line and reconnect fuel line to
proceed as follows: HMU.
(a). Field fabricate a primer bulb assem- (i). Crank engine for approximately 15
bly (Ref. Figure 201). seconds to verify fuel to fuel nozzle is
(b). Disconnect fuel line between CEFA free of air in the system.
and HMU at HMU side. (j). Repeat above procedure as required.
(c). Disconnect fuel line from fuel nozzle. (k). Reinstall fuel line to fuel nozzle.
(d). Install primer bulb assembly in line (l). Close throttle.
between HMU GEAR INLET and the
CEFA. (m). Close fuel shutoff valve.
CLAMPS
BULB PRIMER 5/16

AN8078 ADAPTER SEASIDE #73800 AN8188 NUT
TYGONTYPE TUBING
(FUEL RESISTANT)
FUEL SYSTEM BLEEDING TOOL

(FIELD FABRICATE)
6G28076
Figure 201. Field Fabricated Fuel System Bleeding Tool
Page 202
Revision 39 280060
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Shutoff Valve Control Cable and grommets to fuel shutoff valve.
Replacement Maintain a cable bend radius greater
than 3.5 inches (8.89 cm).
A. Fuel Shutoff Valve Control Cable
Removal (2). Secure forward end of cable in instru-
ment panel with lockwasher and
(Ref. Figure 401)
jamnut.
(1). Remove left aft access panel from
passenger/cargo compartment floor. (3). Slip control cable wire through fuel
shutoff valve lever swivel.
(2). Disconnect control cable from fuel
shutoff valve swivel. (4). Secure end of cable housing to cell cover
with a clamp, washer and screw.
(3). Remove control cable tyraps and
clamps. (5). Install remaining clamps and tyraps.
(4). Remove instrument panel left fairing (6). Rig cable with shutoff valve lever hard
and lower cover panels. against open stop. Adjust cable to get a
(5). Completely back jamnut away from 0.090 0.150 inch (2.29 3.81 mm) gap
cable plunger housing (Ref. Figure 401, between bottom of control knob and
view A). cable housing end fitting. Tighten cable
swivel pinch nut. Install cotter pin.
NOTE: Attach a trace wire or cord to the valve
end of the cable before pulling assembly out Control action must move valve
CAUTION to full open against mechanical
of the instrument panel. Trace will guide re-
placement cable into correct position. stop without bottoming control knob on
cable housing. Control cable operation shall
(6). Pull cable assembly out through be smooth with no binding.
washer, jamnut and instrument panel.
(7). Pull valve control knob out with a
B. Fuel Shutoff Valve Control Cable spring scale. Required valve actuation
Installation force not to be more than 12 pounds
(Ref. Figure 401) (5.443 kg).
Pulling detent knob out of cable (8). Repair, adjust or replace valve control
CAUTION housing two or more inches may system components to meet force limit.
result in loss of the detent ball.
(9). Install left aft fuel cell access panel
(1). Thread cable assembly aft through from passenger/cargo compartment
instrument panel, lockwasher, jamnut floor.
Page 401
280060 Revision 19
MAINTENANCE MANUAL
PLUNGER
HOUSING
CABLE
PLUNGER DETENT
INSTRUMENT RELEASE
PANEL
0.0900.150 INCH
(2.293.81 MM) SPRING
DETENT
BALL DETENT
RELEASE
LOCKWASHER
CABLE
PLUNGER
PLUNGER
NUT HOUSING
HOL INSTRUMENT
E PANEL
CABLE
HOUSING
ENGINE FEED HOSE SHUTOFF
VALVE TO FIREWALL
FUEL SHUTOFF CONTROL KNOB ASSEMBLY
VALVE
MOTIVE FLOW HOSE WASHER

FIREWALL TO FUEL CELL NUT
WASHER
SUPPORT CLAMP
BRACKET
FUEL SHUTOFF
CABLE SCREW SCREW
SCREW
WASHER
SCREW CABLE CLAMP WASHER
HOUSING
WASHER CLAMP
CLAMP
BRACKET
WASHER GROMMET
NUT
PLUG STA
0.000
6G28021A
Figure 401. Fuel Shutoff Valve Cable Installation
Page 402
Revision 19 280060
MAINTENANCE MANUAL
2. Fuel Shutoff Valve Replacement (6). Unclamp and disconnect control cable
from fuel shutoff valve (Ref. Fuel
Avoid fuel vapor ignition Shutoff Valve Control Cable Replace-
WARNING and fire. Use only nonspark- ment).
ing tools and explosion proof work
lights. Attach helicopter to an ap- Handle fuel cell cover with care.
proved electrical ground. Switch OFF CAUTION Prying cover from cell opening
all electrical power. Disconnect exter- or rough handling may damage seal or cell
nal power and battery before opening fitting.
quately ventilated. (7). Unbolt cell access cover. Prop cover
open with suitably padded blocks.
CAUTION (8). Using a backup wrench on valve,
separate engine feed fuel cell supply
D Air in fuel system may cause power hose from fuel shutoff valve.
surges or flameout. Bleed off trapped air
after opening system at any point be- (9). Remove fuel shutoff valve attaching
tween fuel tank and engine fuel nozzle. hardware.
stall caps on the ends of hoses, tubes and B. Fuel Shutoff Valve Installation
fittings as parts are removed. Bag and (Ref. Figure 402)
identify small parts to prevent loss or
damage.
(1). Defuel helicopter. Drain remaining fuel (Ref. Section 910000)
from cell sump drain valve into a Item Nomenclature
suitable container. CM114 Petrolatum
(2). Disconnect electrical power.
A. Fuel Shutoff Valve Removal (1). Apply a coating of petrolatum (CM114)
to a new fuel shutoff valve/cover
(Ref. Figure 402) sealwasher.
(1). Remove left aft fuel cell access panel (2). Install fuel shutoff valve with seal-
from passenger/cargo compartment washer and nut. Use a backup wrench
floor. on shutoff valve so it will not rotate.
Torque nut 240 280 inchpounds
(2). Disconnect fuel quantity probe wire (27.12 31.64 Nm).
harness connector from cell cover
receptacle. (3). Connect engine feed fuel supply hose to
fuel shutoff valve. Using a backup
(3). Unfasten and remove Sta. 91.00 and wrench on valve, torque fuel supply
102.00 left aft fuel cell cover support hose 230 260 inchpounds (25.99
brackets. 29.38 Nm).
(4). Disconnect motive flow fuel hose (4). Start bolts onto aft fuel cell access
assembly between Sta 124.00 bulkhead cover.
and fuel cell access cover. Use backup
wrench on check valve so it will not (5). Install and fasten Sta. 91.00 and 102.00
rotate. left fuel cell cover support brackets.
(5). Disconnect engine feed fuel supply hose (6). Connect engine feed fuel supply hose
assembly between fuel shutoff valve assembly between fuel shutoff valve
and Sta. 124.00 bulkhead. Use backup and Sta. 124.00 bulkhead. Torque hose
wrench on fuel shutoff valve so it will assembly 230 260 inchpounds
not rotate. (25.99 29.38 Nm).
Page 403
280060 Revision 19
MAINTENANCE MANUAL
CAP ENGINE FEED HOSE

SHUTOFF SHUTOFF VALVE TO FIREWALL
BULKHEAD VALVE
UNION MOTIVE FLOW HOSE
FIREWALL TO FUEL CELL
BOL SEALING SEALING
T WASHER WASHER
WASHER
SCREW
SCREW
WASHER
WASHER
REF.
REF. NUT CARGO FLOOR
CARGO FLOOR STRUCTURE
STRUCTURE WASHER
BRACKET
BRACKET ASSEMBLY
ASSEMBLY
BOLT
WIRE WASHER
HARNESS
RECEPTACLE
NUT ACCESS COVER
FUEL INLET BOLT

HOSE ASSEMBLY WASHER WASHER
SEALING WASHER
NUT
SUBMERGED SEALING
MOTIVE FLOW WASHER BULKHEAD
HOSE ASSEMBLY ELBOW
REF. CARGO
FLOOR STRUCTURE
CHECK
VALVE
BOLT
WASHERS
BRACKET
ASSEMBLY
WASHER
NUT
FUEL CELL SCAVENGE
HOSE ASSEMBLY BRACKET ASSEMBLY
6G28022
Figure 402. Fuel Shutoff Valve and Fuel Cell Cover Installation
Page 404
Revision 19 280060
MAINTENANCE MANUAL
(7). Connect motive flow fuel hose assembly (a). Remove right side floor panels from
between Sta 124.00 bulkhead and fuel passenger/cargo compartment floor.
tank access cover. Torque hose assem-
bly 55 65 inchpounds (6.21 7.34 (b). Remove bonding jumpers then
Nm). remove fuel cell access cover bolts
and washers.
(8). Connect fuel quantity transmitter
(2). To remove left aft fuel cell access cover
(Ref. Figure 402):
(9). Progressively torque fuel cell cover (a). Remove left aft fuel cell access panel
bolts to 70 90 inchpounds (7.91 from passenger/cargo compartment
10.17 Nm) in a cross pattern. floor.
(10). Clamp and connect control cable to fuel (b). Unclamp and disconnect control
shutoff valve. Rig fuel shutoff valve cable from fuel shutoff valve (Ref.
control cable (Ref. Fuel Shutoff Valve Figure 401).
Control Cable Replacement).
(c). Disconnect engine feed fuel supply
(11). Install left aft access passenger/cargo hose assembly between fuel shutoff
compartment floor panel. valve and Sta. 124.00 bulkhead. Use
backup wrench on fuel shutoff valve
3. Fuel Cell Cover Replacement so it will not rotate.
Avoid fuel vapor ignition (d). Disconnect motive flow fuel hose
WARNING and fire. Use only nonspark- assembly between Sta 124.00 bulk-
ing tools and explosion proof work head and fuel cell access cover.
lights. Attach helicopter to an ap- (e). Disconnect fuel quantity probe wire
proved electrical ground. Switch OFF harness connector from fuel cell cover
all electrical power. Disconnect exter- receptacle.
fuel system. Ensure work area is ade- (f). Unfasten and remove Sta. 91.00 and
quately ventilated. 102.00 left aft fuel cell cover support
brackets.
CAUTION (g). Remove cover bolts and washers.
Prop cover open with suitably padded
D Air in fuel system may cause power blocks.
surges or flameout. Bleed off trapped air
after opening system at any point be- (h). Using a backup wrench on valve,
tween fuel tank and engine fuel nozzle. separate engine feed fuel cell supply
hose from fuel shutoff valve and fuel
inlet from fuel cell access cover.
stall caps on the ends of hoses, tubes and
fittings as parts are removed. Bag and (i). Disconnect submerged motive flow
identify small parts to prevent loss or fuel hose assembly between fuel
damage. check valve and ejector pump from
fuel cell access cover.
from cell sump drain valve into a (j). Disconnect fuel cell scavenge hose
suitable container. assembly from bottom of fuel cell
access cover bracket assembly to
(2). Disconnect electrical power. ejector pump (Ref. Figure 404).
A. Fuel Cell Cover Removal (k). Cut safety wire from fuel probe
electrical connector base nut and
(1). To remove right side fuel cell access remove connector from fuel cell
covers (Ref. Figure 406). access cover.
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280060 Revision 19
MAINTENANCE MANUAL
(l). If applicable, remove fuel cell scav- jamnut to 240 280 inchpounds
enge hose bracket assembly,bulkhead (27.12 31.64 Nm).
union and fuel shutoff valve from fuel
cell cover. (d). Install support bracket to cover with
bolts, washer, and sealwashers.
Apply a coating of petrolatum
B. Fuel Cell Cover Installation
(CM114) to sealwasher. Torque bolts
36 46 inchpounds (4.06 5.19
Consumable Materials Nm).
(Ref. Section 910000) (e). Install bulkhead union to cover with
Item Nomenclature sealwasher next to union. Apply a
CM114 Petrolatum coating of petrolatum (CM114) to
CM124 Kerosene sealwasher. Install washer and
jamnut. Torque jamnut to 120 150
CM702 Lockwire CRES
Install cap outside of cell. Torque cap
to 110 130 inchpounds (12.43
(1). Wipe fuel cell and cover sealing sur-
14.69 Nm).
faces clean with kerosene (CM124) on a
clean lint free cloth. (5). Place left forward fuel cell access cover
into position on fuel cell.
(2). Inspect fuel cell cover seals for debond-
ing, nicks or cuts and any other damage (6). Connect fuel quantity probe wire
having a leak producing potential. harness connector to cell cover. Torque
Replace covers or left aft cover as connector jamnut and safetywire to
required. bulkhead union with (CM702) lockwire.
(3). Install bonding jumper with right cell CAUTION

access covers, bolts and washers (Ref. D On early aircraft, the fuel inlet hose and
Figure 406). Progressively torque cover the fuel cell scavenge hose have the same
bolts to 70 90 inchpounds (7.91 size end fitting. Care must be taken to not
10.17 Nm) in a cross pattern. misconnect these two hoses (Ref.
Figure 404).
(4). To install left aft fuel cell access cover
(Ref. Figure 402): D The fuel inlet hose is the hose that runs
from the fuel inlet fitting at the bottom of
(a). Apply a coating of petrolatum the fuel cell aft of the fuel cell baffle.
(CM114) to a new fuel shutoff valve/c- D The fuel cell scavenge hose is the hose
over sealwasher. Install valve on cell that runs forward over the fuel cell baffle.
cover with sealwasher next to valve (7). Install left hand fuel inlet hose assem-
body and valve properly aligned to bly to access cover fuel shutoff valve.
make connection with valve control Torque hose assembly 230 260
cable. Install and torque valve inchpounds (25.99 29.38 Nm).
jamnut to 240 280 inchpounds
(27.12 31.64 Nm). (8). Install submerged motive flow hose
assembly to access cover check valve.
(b). Apply a coating of petrolatum Torque hose assembly 50 65 inch
(CM114) to sealwasher. Install check pounds (5.65 7.34 Nm).
valve and sealwasher to inside cover
(9). Install scavenge fuel cell hose assembly
and a plain washer outside. Install
to access cover bulkhead elbow. Torque
jamnut and torque to 85 105
hose assembly 230 260 inchpounds
(25.99 29.38 Nm).
(c). Install bulkhead elbow to support (10). Install three support brackets on Sta.
bracket. with washer and nut. Torque 91.00 and 102.00 floor crossmembers
Page 406
Revision 34 280060
MAINTENANCE MANUAL
with washers and screws. Torque (1). Defuel helicopter. Drain remaining fuel
screws to 20 25 inchpounds (2.26 from tank sump drain valve into a
2.82 Nm). suitable container.
(11). Install cover bolts and washers. (2). Cap fittings and lines as required.
Progressively torque cover bolts to 70
A. Fuel Supply Lines Removal
90 inchpounds (7.91 10.17 Nm) in
a cross pattern. (Ref. Figure 402, Figure 403 and Figure 404)
(12). Connect engine feed fuel supply hose to (1). Remove left aft fuel cell access panel
fuel shutoff valve. Torque hose nut to from passenger/cargo compartment
230 260 inchpounds (25.99 29.38 floor.
Nm).
(2). Disconnect motive flow fuel hose
(13). Connect fuel motive flow hose to access assembly between Sta 124.00 bulkhead
cover/check valve. Torque hose nut (50 and fuel cell access cover. Use backup
65 inchpounds (5.65 7.34 Nm). wrench so fittings will not rotate.
(14). Connect fuel quantity probe connector (3). Disconnect engine feed fuel supply hose
to wire harness receptacle. assembly between fuel shutoff valve
and Sta. 124.00 bulkhead. Use backup
(15). Slip control cable through hole in fuel wrench on fittings so they will not
shutoff valve lever swivel. rotate.
(16). Rig cable control system (Ref. Fuel (4). Remove Sta. 91.00 and Sta.102.00 fuel
Shutoff Valve Control Cable Replace- cell cover support brackets.
ment). (5). Remove clamps and attaching hard-
(17). Apply a torque alignment stripe to fuel ware from passenger/cargo compart-
line tube, hose and fitting fasteners. ment floor.
(6). Remove engine feed fuel supply hose
(18). Install access panels on passenger
and motive flow fuel hose assemblies.
cargo compartment floor.
(7). Remove Sta. 124.00 bulkhead unions.
4. Fuel Supply Lines Replacement
B. Fuel Supply Lines Installation
WARNING and fire. Use only nonspark- (Ref. Figure 402, Figure 403 and Figure 404)
ing tools and explosion proof work (1). Install Sta. 124.00 firewall bulkhead
lights. Attach helicopter to an ap- unions, with washer and jam nut on
proved electrical ground. Switch OFF forward side of firewall. Torque engine
all electrical power. Disconnect exter- feed fuel supply union nut to 240 280
nal power and battery before opening inchpounds (27.12 31.64 Nm).
fuel system. Ensure work area is ade- Torque fuel return bypass union to 85
quately ventilated. 105 inchpounds (9.60 11.86 Nm).
CAUTION (2). Connect fuel cell engine feed supply

hose to fuel shutoff valve and bulkhead
D Air in fuel system may cause power union. Use a backup wrench on valve
surges or flameout. Bleed off trapped air and bulkhead union. Torque fuel supply
after opening system at any point be- hose 230 260 inchpounds (25.99
tween fuel tank and engine fuel nozzle. 29.38 Nm).
D Prevent fuel system contamination. In- (3). Connect motive flow fuel hose assembly
stall caps on the ends of hoses, tubes and between Sta 124.00 bulkhead and fuel
fittings as parts are removed. Bag and tank access cover. Torque hose assem-
identify small parts to prevent loss or bly 50 65 inchpounds (5.65 7.34
damage. Nm).
Page 407
280060 Revision 34
MAINTENANCE MANUAL
NUT
WASHER
BULKHEAD
UNION
NUT
ENGINE FEED HOSE
SHUTOFF VALVE TO FIREWALL WASHER
BULKHEAD
UNION
SCREW MOTIVE FLOW HOSE

REF. STA 113.85 FIREWALL TO FUEL CELL
CARGO FLOOR WASHER
CLAMP CLAMP
SCREW
WASHER WASHER
REF. STA 102.23
CARGO FLOOR NUT
CLAMP
CLAMP
REF. TO FUEL CELL

COVER
WASHER
NUT
6G280241
Figure 403. Fuel Lines Installation
Page 408
Revision 19 280060
MAINTENANCE MANUAL
HOSE ASSEMBLY
BOLT
WASHER
SEALING WASHER
FUEL INLET
SUPPLY HOSE CHECK
ASSEMBLY VALVE NUT
AFT FUEL SUBMERGED

PROBE MOTIVE FLOW WASHER
HOSE ASSEMBLY
BOLT BULKHEAD ELBOW

WASHER
BONDING
JUMPER
BOLT BOLT BRACKET
ASSEMBLY
WASHER
FUEL INLET WASHERS NUTPLATE
FITTING ASSEMBLY WASHER
NUT
FUEL CELL SCAVENGE
HOSE ASSEMBLY
BRACKET ASSEMBLY
EJECTOR
NUTPLATE PUMP
BOLT
WASHER
EJECTOR FUEL CELL

BRACKET ASSEMBLY SCAVENGE
HOSE ASSEMBLY
SPACER
SUBMERGED
MOTIVE FLOW CLAMP
HOSE ASSEMBLY
ORING WASHER
BOLT
EJECTOR PUMP
ELBOW
REDUCER FORWARD
BUSHING FUEL PROBE
NUT
ORING
6G280242
Figure 404. Ejector Pump and Fuel Lines Installation
Page 409
280060 Revision 19
MAINTENANCE MANUAL
(4). Apply a torque alignment stripe to fuel A. Fuel Cell Vent System Components
line tube, hose and fitting fasteners. Removal
(5). Apply chaffing tape between hose (Ref. Figure 405)

assemblies and fuel cell cover assembly
to prevent chaffing. (1). Remove fuel vent cross over tube access
cover and Sta.78.50 chanted bulkhead
(6). Secure engine feed hose assembly and stress panel.
motive flow hose assembly underneath (2). Remove flame arrestor/tube assembly
passenger/cargo floor with clamps and with clamps and attaching hardware.
attaching hardware.
(3). Disconnect hoses from vent crossover
(7). Secure fuel cell to Sta. 91.00 and tube and attaching hardware and
Sta.102.00 cell cover support brackets. remove crossover tube.
(8). Install aft fuel cell access panel from (4). Remove passenger/cargo compartment
passenger/cargo compartment floor. floor fuel cell access panels.
(5). Disconnect hoses from aft fuel vent
5. Fuel Cell Vent System Components valves, remove bonding jumper and
Replacement attaching hardware from vent tubes
and remove fuel vent tubes from under
Avoid fuel vapor ignition cargo floor.
ing tools and explosion proof work (6). Remove bonding jumper and fell cell
lights. Attach helicopter to an ap- access covers as required.
proved electrical ground. Switch OFF
all electrical power. Disconnect exter- (7). Remove retaining ring and spring from
nal power and battery before opening fuel vent valve and remove fuel vent
fuel system. Ensure work area is ade- valve from inside of fuel cell.
quately ventilated.
B. Fuel Cell Vent System Components
Prevent fuel system contamina- Installation
hoses, tubes and fittings as parts are re- (Ref. Figure 405)
vent loss or damage. Consumable Materials
(1). Defuel helicopter. Drain remaining fuel Item Nomenclature
CM114 Petrolatum
suitable container.
(2). Disconnect electrical power. CM702 Lockwire CRES
Prevent spontaneous com-

WARNING bustion or explosion. Never (1). Coat Orings with (CM114) lubricant
use oxygen to purge or ventilate fuel and install on vent valves.
tank or fuel system components. Fuel, (2). Insert vent valves thru cell from inside
either vapor or liquid, will violently and secure using springs and retainers.
(3). Bond prep aft vent fittings at bond
(3). Ventilate fuel tank with an inert gas, jumper location.
such as nitrogen, or low pressure
compressed air applied through filler (4). Coat Orings with lubricant (CM114)
neck. and install on vent fittings.
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Revision 19 280060
MAINTENANCE MANUAL
BOLT
WASHER
SCREW BONDING
REF. FS 78.50 JUMPER
CANTED BULKHEAD WASHER
BOLT FLAME VENT CLAMP

WASHER ARRESTOR TUBE
(3 PLCS) WASHER
CLAMP
SCREW NUT
WASHER VENT
WASHER NUT FITTING
(3 PLCS)
TUBE ASSEMBLY
NUT
(3 PLCS)
CLAMP
CLAMP SCREW
(3 PLCS) WASHER
NUT
GROMMET
CONNECTOR
NUT
(2 PLCS)
WASHER
(2 PLCS) BOLT
CLAMP (2 PLCS)
(2 PLCS) HOSE WASHER
(2 PLCS) (2 PLCS)
TUBE ASSEMBLY
WASHER
(2 PLCS) CLAMP
(2 PLCS)
FLAME
ARRESTOR CROSSOVER
(2 PLCS) ASSY
BOLT (2 PLCS) 0RING
WASHER
(2 PLCS) RETAINING
SPACER NUT WASHER RING (2 PLCS)
(2 PLCS) (2 PLCS) (2 PLCS)
SPRING
BOLT RETAINER
CLAMP PIN (2 PLCS) 0RING
WASHER
WASHER NUT
VENT VALVE
(2 PLCS)
6G28023
Figure 405. Fuel Cell Vent System Components
Page 411
280060 Revision 19
MAINTENANCE MANUAL
(5). Install aft vent fittings and bond (21). Safety connector to crossover tube
jumpers to vent valves with hardware. with lockwire (CM702).
Torque bolts to 36 46 inchpounds
(4.0 5.2 Nm). (22). Tierap tube assembly to forward
bulkhead of Sta. 78.50.
(6). Bond prep six vent tube clamp screw
(23). Route tube assembly to vent fairing and
holes on cargo deck.
bond using sealant (CM425).
(7). Install hoses to aft vent fittings with (24). Bond prep fuel cell access covers.
lockwire (CM702), two wrap around
turns minimum. (25). Install bonding jumpers and fell cell
access covers. Torque bolts 70 90
(8). Slide vent tubes under cargo floor and inchpounds (7.91 10.17 Nm).
connect to hoses with lockwire Install fuel vent access cover.
(CM702), two wrap around turns
minimum. (26). Install passenger/cargo compartment
floor access panels.
(9). Attach forward end of tube to cargo
floor with clamps. 6. Fuel Cell Replacement
(10). Install bonding jumpers at aft clamps. Avoid fuel vapor ignition
(11). Install hoses on forward ends of vent ing tools and explosion proof work
tubes and safety using lockwire lights. Attach helicopter to an ap-
(CM702), two wrap around turns proved electrical ground. Switch OFF
minimum. all electrical power. Disconnect exter-
(12). Coat Orings with lubricant (CM114) fuel system. Ensure work area is ade-
and install on crossover tube. quately ventilated.
(13). Attach vent crossover tube with
hardware to tops of vent valves. Torque CAUTION
bolts to 36 46 inchpounds (4.06 D Do not work on cell in ambient tempera-
5.19 Nm). tures below 70F (21C).
(14). Bond prep two nutplate holes for D Prevent fuel system contamination. In-
attaching crossover tube. stall caps on the ends of hoses, tubes and
(15). Install clamps on crossover tube and identify small parts to prevent loss or
attach to airframe. damage.
(16). Install grommet in Sta. 78.50 skin at (1). Defuel helicopter. Drain remaining fuel
vent outlet using epoxy adhesive from tank sump drain valve into a
(CM411). suitable container.
(17). Attach connector to the flame arrestor (2). Disconnect electrical power.
and safety with lockwire (CM702), two A. Fuel Cell Removal
wrap around turns minimum.
(Ref. Figure 406)
(18). Attach tube to flame arrestor and
safety with lockwire (CM702) two wrap NOTE: The following procedures are required
around turns minimum. to access and separate the fuel cell intercon-
nect fitting, vent system and gravity fill port
(19). Bond prep one of the three attaching before either cell can be removed from its
screw holes for the flame arrestor. bay.
(20). Install flame arrestor/tube assembly (1). Remove forward fuel vent crossover
with clamps. tube cover, right and left fuel cell access
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Revision 19 280060
MAINTENANCE MANUAL
panels from passenger/cargo compart- (11). Disconnect submerged fuel cell scav-
ment floor. enge hose assembly from bottom of fuel
cell access cover bracket assembly to
(2). Disconnect fuel quantity probe wire ejector pump (Ref. Figure 404).
harness connector from fuel cell access
cover receptacle. (12). Cut safety wire from fuel probe electri-
cal connector base nut and remove
(3). Unclamp and disconnect control cable connector from fuel cell access cover.
from fuel shutoff valve. (13). Unbolt and remove right hand fuel cell
access cover(s) and bonding jumpers.
(4). Unfasten and remove Sta. 91.00 and Remove left hand forward fuel cell
102.00 left fuel cell cover support access cover.
brackets from passenger/cargo floor
structure (Ref. Figure 402). Prevent spontaneous com-
(5). Remove attaching hardware from Sta use oxygen to purge or ventilate fuel
102.230 and Sta 113.850 passenger/car- tank or fuel system components. Fuel,
go compartment floor structure that either vapor or liquid, will violently
secures engine feed fuel supply hose react with an oxygen rich atmosphere.
and motive flow firewall to fuel cell
hose to bottom of floor (Ref. (14). Mop up any remaining fuel in both cells
Figure 403). with clean lint free cloth. Purge fuel
cells with dry, forced air or inert gas
(6). Disconnect engine feed fuel supply hose such as nitrogen through filler neck.
between fuel shutoff valve and firewall
(15). Disconnect wire harness from forward
Sta. 124.00 bulkhead union. Using a
and aft fuel quantity probe and remove
backup wrench on bulkhead union so it
wire harness (Ref. Fuel Quantity Probe
will not rotate, disconnect and remove
Replacement).
engine feed fuel supply hose assembly
(Ref. Fuel Supply Line Replacement). (16). Remove aft fuel quantity probes, fuel
inlet with fuel supply hose and bracket
(7). Disconnect motive flow fuel hose assembly, forward fuel quantity probe,
assembly between fuel cell access cover ejector pump with submerged motive
and Sta 124.00 bulkhead. Using a flow fuel hose assembly and fuel cell
backup wrench on bulkhead union so it scavenge hose as a subassembly (Ref.
will not rotate, disconnect and remove Figure 404 and Figure 407).
motive flow fuel hose assembly.
(17). Disconnect and remove fuel vent
Handle fuel cell covers with system components necessary to
CAUTION care. Prying covers from cell remove fuel cell (Ref. Fuel Cell Vent
openings or rough handling may damage System Component Replacement).
the cover seal or cell fitting.
NOTE: At this point either cell may be re-
(8). Unbolt and prop left aft fuel cell access moved, as required.
cover open with suitably padded blocks. (18). Remove sump drain valve.
(9). Disconnect fuel inlet supply hose (19). Remove retaining ring and spring from
between fuel shutoff valve fuel cell fuel cell interconnect fittings (Ref.
access cover and fuel inlet support Figure 406).
bracket (Ref. Figure 402 and
Figure 404). (20). Remove cell suspension cords.
(21). For right fuel cell removal:
(10). Disconnect submerged motive flow fuel
hose assembly between fuel check valve (a). Remove fuel filler neck fairing from
fuel cell access cover and ejector pump. passenger/cargo compartment floor.
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280060 Revision 19
MAINTENANCE MANUAL
(b). Unclamp fuel gravity filler port from cell. Coat Orings with lubricant
fill valve, remove hose from fill valve (CM114) and install Oring, spring and
and disconnect lanyard. retaining ring.
Cells are thinwalled and frag- Cells are thinwalled and frag-
CAUTION CAUTION ile. Avoid snagging or dragging
ile. Avoid snagging or dragging
cell over pointed or sharp edges. Do not cell over pointed or sharp edges. Do not
scratch or nick any of the cells metal fit- scratch or nick any of the cells metal fit-
tings. tings. Avoid hard contact between cell and
fuselage structure when inserting.
(22). Collapse and fold cell lengthwise and
remove through floor access opening. (4). Fold cells lengthwise and position in
bay through floor opening. Unfold cell
B. Fuel Cell Installation and smooth out all creases.
(Ref. Figure 406) (5). Align cell openings with airframe
openings. Hook up fuel cell cross over
Consumable Materials interconnects into right fuel cell. Coat
(Ref. Section 910000) Orings with lubricant (CM114) and
Item Nomenclature install Oring, spring and retaining
CM114 Petrolatum ring.
CM220 Naphtha aliphatic (6). Install a new Oring on sump drain
CM702 Lockwire CRES valve. Install valve and torque to 95
CM809 Nylon cord 105 inchpounds (10.73 11.86 Nm).
Safety wire drain valve with lockwire
(CM702).
WARNING and fire. Use only nonspark- (7). For right fuel cell installation:
ing tools and explosion proof work (a). Install rubber hose to fill valve and
lights. Attach helicopter to an ap- filler neck, hose should be approxi-
proved electrical ground. Switch OFF mately six an one half inches (16.5
all electrical power. Disconnect exter- cm) long. Secure hose to fill valve and
nal power and battery before opening filler neck with clamps.
quately ventilated. (b). Insure lanyard on filler valve is
accessible with fill cap removed. Slip
NOTE: Discard used Orings and sealwashers. lanyard on fuel cap onto ring of fill
Apply a thin coat of petrolatum (CM114) to valve. Install fuel cap.
all new Orings except cell vent system
(c). Connect lanyard of fill valve to
sealwashers.
gravity filler port. Install hose and
(1). Airvacuum all debris from cell bays. clamp.
Ensure compartment liner will protect (8). Connect engine feed fuel supply hose
cell from airframe points and edges. and motive flow fuel hose assembly to
Repair liner as required. Sta. 124.00 bulkhead union (Ref. Fuel
(2). Bond prep fill valve with fuel cell Supply Line Replacement).
fitting. Coat Orings with lubricant (9). Install fuel vent system components
(CM114) and install fill valve into right (Ref. Fuel Vent System Components
fuel cell with Oring, spring and Replacement).
retaining ring. Ensure clocking of fill
valve with flat at top lines up with (10). Route suspension nylon cord (CM809)
shoulder on fuel cell fitting. thru grommet of fuel cell and thru
eyelets of fuselage. Tighten and tie cord
(3). Hook up fuel cell interconnect fittings using a bowline knot. Cut excess cord
into left fuel cell. Ensure short end of after knot to approximately 3 to 4
interconnects are facing into left fuel inches (7.6 cm to 10.2 cm) in length.
Page 414
Revision 43 280060
MAINTENANCE MANUAL
(11). Secure opposite end of cord using a (13). Aft fuel probe and fuel supply inlet hose
truckers slip knot. Cut excess cord installation (Ref. Ejector Pump and
after knot to approximately 3 to 4 Fuel Line Installation):
inches (7.6 cm to 10.2 cm) in length.
(a). Bond attachment holes on fuel cell
(12). Forward fuel probe and ejector pump aft sump fitting assembly, bracket
subassembly installation (Ref. Ejector assembly, aft fuel probe attachment
Pump and Fuel Line Installation): holes and fuel inlet fitting assembly.
(a). Bond prep ejector pump bracket (b). Install fuel inlet fitting assembly to
assembly with forward fuel probe and bracket assembly with four washers
ejector pump assembly. each between fuel inlet fitting and
bracket assembly.
(b). Coat Orings with lubricant (CM114)
and install reducer bushing with (c). Install aft fuel probe to bracket
Orings into ejector pump. Torque to assembly and fuel cell aft sump
50 65 inchpounds (5.65 7.34 fitting with bolts and two washers
Nm). under the head of each bolt, except
bolt with ground wire, only one
(c). Coat Orings with lubricant (CM114) washer is required.
and install jamnut, bulkhead elbow
to reducer bushing. Torque jamnut to (d). Connect wire harness to aft fuel
85 105 inchpounds (9.60 11.86 probe. Attach bonding jumper to
Nm). outboard bolt of probe. Torque bolts
to 36 46 inchpounds (4.06 5.19
(d). Install fuel cell scavenge hose to Nm) (Ref. Fuel Quantity Probe
ejector pump. Torque hose nut to 230 Replacement).
260 inchpounds (25.99 28.81
Nm).
(14). Install attaching hardware from Sta
102.230 and Sta 113.850 passenger/car-
(e). Install submerged motive flow fuel
go compartment floor structure that
hose assembly to elbow and torque to
secures engine feed fuel supply hose
50 65 inchpounds (5.65 7.34
and motive flow firewall to fuel cell
Nm).
hose to bottom of floor (Ref.
Figure 403).
(f). Bond prep ejector pump in area of
clamp up and install forward fuel
quantity probe, ejector pump with (15). Install right hand fuel cell access
submerged motive flow hose assem- covers, left hand forward and left hand
bly and fuel cell scavenge hose aft access cover (Ref. Fuel Cell Cover
assembly as a subassembly. Replacement).
(g). Install ejector pump subassembly to (16). Connect fuel quantity probe wire
bracket assembly with clamps, bolts harness connector from fuel cell access
and washers. Torque bolts to 36 46 cover receptacle.
(17). Connect and clamp control cable from
(h). Connect wire harness to forward fuel fuel shutoff valve (Ref. Fuel Shutoff
probe. Route submerged motive flow Valve Control Cable Replacement).
fuel hose assembly, fuel cell scavenge
hose assembly and wire harness thru (18). Install forward fuel vent crossover tube
fuel cell fabric retaining loops and cover, right and fuel cell access panels
baffle (Ref. Fuel Quantity Probe from passenger/cargo compartment
Replacement). floor.
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MAINTENANCE MANUAL
RETAINING
RING
SPRING
INTERCONNECT
SPRING RETAINING
RING
BL
0.000
CENTER BEAM ORING
ASSEMBLY
RETAINING
RING SPRING
RETAINING
RING
INTERCONNECT
SPRING
RIGHT
LEFT FUEL CELL
FUEL CELL
ORING
6G280251
Figure 406. Fuel Cell Interconnect and Support Lacing (Sheet 1 of 3)
Page 416
Revision 19 280060
MAINTENANCE MANUAL
START HERE
BOWLINE KNOT END HERE
TRUCKER SLIPKNOT
BONDING
JUMPER
END HERE START HERE

TRUCKER SLIPKNOT BOWLINE KNOT
FUEL CAP
FILL PORT
HOS
E
RETAINING
RING
CLAMP SPRING
LANYARD ORING
CLAMP
BOWLINE KNOT
RIGHT
FUEL CELL
FILL
VALVE
VIEW LOOKING AFT

AT VALVE INLET
6G280252
Page 417
280060 Revision 19
MAINTENANCE MANUAL
TRUCKER SLIPKNOT
6G280253
LEFT
BAFFLE
RIGHT
BAFFLE
GROMMET
(6 PLCS)
FLAPPER CHECK VALVE

IN CLOSED POSITION
FLAPPER CHECK VALVE

VIEW LOOKING FORWARD IN OPEN POSITION

6G28044
Page 418
Revision 19 280060
MAINTENANCE MANUAL
7. Fuel Filler Neck Gravity Fill Port (4). Insure lanyard on filler valve is
Replacement accessible with fill cap removed. Slip
lanyard on fuel cap onto ring of fill
(Ref. Figure 406) valve. Install fuel cap.
Avoid fuel vapor ignition (5). Connect lanyard of fill valve to gravity
WARNING and fire. Use only nonspark- filler port. Install hose and clamp.
lights. Attach helicopter to an ap- 8. Fuel System Drain Valve Replacement
proved electrical ground. Switch OFF Avoid fuel vapor ignition
all electrical power. Disconnect exter- WARNING and fire. Use only nonspark-
nal power and battery before opening ing tools and explosion proof work
fuel system. Ensure work area is ade- lights. Attach helicopter to an ap-
quately ventilated. proved electrical ground. Switch OFF
Helicopter must be defueled and
CAUTION drained prior to removing grav-
ity fill port. quately ventilated.
(1). Defuel helicopter. Drain remaining fuel Helicopter must be defueled and
from cell sump drain valve into a CAUTION drained prior to removing tank
suitable container. sump drain valve.
(2). Disconnect electrical power. (1). Defuel helicopter, as required. Drain
remaining fuel from tank sump drain
A. Fuel Filler Neck Gravity Fill Port Removal valve into a suitable container.
(1). Remove fuel filler neck fairing from (2). Disconnect electrical power.
passenger/cargo compartment floor.
A. Fuel System Drain Valve Removal
(2). Unclamp fuel gravity filler port from fill (1). Remove lockwire from tank sump drain
valve, remove hose from fill valve and valve.
disconnect lanyard.
(2). Using appropriate socket or wrench,
(3). Remove bolts and washers from filler remove drain valve.
neck mounting flange and remove
gravity fill port. B. Fuel System Drain Valve Installation
B. Fuel Filler Neck Gravity Fill Port Consumable Materials

Installation (Ref. Section 910000)
Item Nomenclature
(1). Bond prep attach points for bonding
jumper near fuel fill area. Attach CM114 Petrolatum
bonding jumper to fuel cell with screw CM124 Kerosene
and washer. Attach opposite end of CM702 Lockwire CRES
bonding jumper to passenger/cargo
compartment flooring with screw, (1). Replace drain valve Oring packings.
washers and nut. Lubricate packings with kerosene
(2). Install bolts and washers from filler (CM124), petrolatum (CM114) or jet
neck mounting flange and install fuel.
gravity fill port. (2). Install and torque sump drain valve to
95 105 inchpounds (10.73 11.86
(3). Install rubber hose to fill valve and
Nm). Safety valve with lockwire
filler neck. Note, hose should be
(CM702).
approximately six an one half inches
long. Secure hose to fill valve and filler (3). Apply a torque alignment stripe to fuel
neck with clamps. line tube, hose and fitting fasteners.
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280060 Revision 19
MAINTENANCE MANUAL
(4). Refuel helicopter. B. Forward Fuel Quantity Probe Installation

(5). Check drain valve for leakage. (Ref. Figure 407)
9. Fuel Quantity Probe Replacement (1). Install fuel quantity probe ground wire
and attaching hardware. Torque bolts
WARNING and fire. Use only nonspark- to 36 46 inchpounds (4.06 5.19
Nm).
lights. Attach helicopter to an ap- (2). Connect wire harness connector ends to
proved electrical ground. Switch OFF forward fuel probe in the same locations
all electrical power. Disconnect exter- as removed.
fuel system. Ensure work area is ade- (3). Bond prep fuel cell access cover.
quately ventilated.
(1). Defuel helicopter. Drain remaining fuel (4). Install left forward fuel cell access
from tank sump drain valve into a cover. Install bonding jumper to fuel
suitable container. cell access cover. Torque bolts to 70 90
inch pounds (7.91 10.17 Nm).
(5). Install left forward fuel cell access
Prevent spontaneous com- panel from passenger/cargo compart-
WARNING bustion or explosion. Never ment floor.
use oxygen to purge or ventilate fuel
tank or fuel system components. Fuel, C. Aft Fuel Quantity Probe Removal
either vapor or liquid, will violently
react with an oxygen rich atmosphere. (Ref. Figure 407)
(3). Ventilate fuel tank with an inert gas (1). Remove left aft fuel cell access panel
such as nitrogen or low pressure from passenger/cargo compartment
compressed air applied through filler floor.
neck.
(2). Remove left aft fuel cell access cover
A. Forward Fuel Quantity Probe Removal (Ref. Fuel Cell Cover Replacement).
(Ref. Figure 407)
(3). Disconnect wire harness connector ends
(1). Remove left forward fuel cell access from aft fuel probe.
panel from passenger/cargo compart-
ment floor. (a). Remove ORANGE wire from termi-
nal L.
(2). Remove left forward fuel cell access
cover. (b). Remove BLUE wire from terminal R.
(3). Disconnect wire harness connector ends (c). Remove WHITE wire from terminal
from forward fuel probe. S.
(a). Remove ORANGE wire from termi- (d). Remove low level switch WHITE wire
nal L. from terminal 1.
(b). Remove BLUE wire from terminal R.
(e). Remove low level switch BLUE wire
(c). Remove WHITE wire from terminal from terminal 2.
S.
(f). Remove GROUND wire from probe
(4). Remove GROUND wire from probe mount flange, remove remaining
mount flange, remaining attachment attachment hardware and remove
hardware and remove probe. probe.
Page 420
Revision 19 280060
MAINTENANCE MANUAL
REF. FUEL CELL

FABRIC LOOPS
FUEL CELL SCAVENGE

HOSE ASSEMBLY
EJECTOR
BRACKET
ASSEMBLY SCAVENGE
HOSE ASSEMBLY
BOL SUBMERGED MOTIVE
T FLOW HOSE
WASHER
BOL WIRE HARNESS

T
WASHER
EJECTOR FORWARD
PUMP FUEL PROBE
FUEL CELL FITTING
FORWARD FUEL PROBE
6G280511A
Figure 407. Fuel Quantity Probes (Sheet 1 of 2)
Page 421
280060 Revision 19
MAINTENANCE MANUAL
AFT FUEL PROBE
BOL
T
BOL WASHER
T
WASHER
GROUND
JUMPER
WASHER
FUEL INLET SUPPLY

HOSE ASSEMBLY
FUEL INLET FITTING ASSEMBLY
BRACKET
ASSEMBLY
AFT FUEL PROBE

6G280512
Figure 407. Fuel Quantity Probes (Sheet 2 of 2)

D. Aft Fuel Quantity Probe Installation (2). Connect wire harness connector ends to
forward fuel probe in the same locations
as removed.
(Ref. Figure 407)
(3). Install left aft fuel cell access cover
(Ref. Fuel Cell Cover Replacement).
(1). Install fuel quantity probe ground wire
and attaching hardware. Torque bolts (4). Install left forward fuel cell access
to 36 46 inchpounds (4.06 5.19 panel from passenger/cargo compart-
Nm). ment floor.
Page 422
Revision 19 280060
MAINTENANCE MANUAL
FUEL SYSTEM
ADJUSTMENT/TEST
1. Fuel Level Low Light/Fuel Quantity (5). Level the helicopter laterally across the
Indicator System Test and Calibration passenger/cargo compartment floor.
The following procedure is for calibrating the (6). Plug in and switch on 27.5 0.5 Vdc
fuel quantity system when the fuel cell, fuel external power. Set BAT master switch
probes or fuel quantity indicator have been to EXT PWR. Make sure the INST and
replaced. PNL LT circuit breakers are pushed in.
NOTE: All readings are taken from the center-
Special Tools line of the fuel quantity indicator pointer.
(Ref. Section 910000) (7). Verify the FUEL LEVEL LOW light is
Item Nomenclature illuminated.
ST203 Hydraulic jack: 15 ton (9004500 kg)
(8). Add 1.3 gals (4.92 Liter) of fuel from a
ST205 Inclinometer
calibrated delivery system to the fuel
cell. This amount of fuel is trapped fuel
Prevent fuel vapor accumu- or unusable fuel. Calibrate empty.
WARNING lation, ignition and fire. At- (a). Calibrate zero on the fuel quantity
tach helicopter to an approved electri- indicator by holding the fuel quantity
cal ground. Switch OFF and disconnect gauging system calibration switch in
external power and battery before the empty calibration position (down)
opening fuel system. Perform work in for a minimum of 5 10 seconds.
an open, well ventilated area away
from all potential ignition sources. Use (b). Verify the the fuel quantity indicator
only nonsparking tools and explosion now reads empty. Empty is the E
proof work lights. with the pointer centerline between
the outer and inner edge of the E
(1). Attach helicopter to a approved electri- graduation mark.
cal ground.
(9). Add 11.4 gals (44.3 Liter) of fuel from a
(2). Defuel and drain fuel cell sumps of all calibrated delivery system to the fuel
fuel from all four sump drains with the cell.
helicopter at normal ground attitude. (10). Verify the FUEL LEVEL LOW light is
not illuminated.
(3). Place an aircraft jack (ST203) under the
aft jacking point. (11). Wait 15 minutes and verify the FUEL
LEVEL LOW light is not illuminated. If
Do not apply more than 500 lb. light illuminates:
CAUTION (227 kg) pressure on aft jacking (a). Inspect baffles for damage, tears,
point, damage to tailboom and attachment punctures or delamination.
points will occur.
(b). Inspect flappers for proper seating.
(4). Locate a inclinometer (ST205) on the Flappers should seat flush with
passenger/cargo compartment floor at gravity or very light finger pressure
approximately fuselage Sta. 100.00 and should move freely.
104.00. Raise the helicopter at Sta. (12). Fill the fuel cell and secure the fuel
303.03 with jack (ST204) and P.Sta. filler cap.
18.76 with jacks (ST203) to obtain a 3
degree nose down simulated flight (a). Calibrate full on the fuel quantity
attitude as observed on the inclinome- indicator by holding the fuel quantity
ter scale. gauging system calibration switch in
Page 501
280060 Revision 22
MAINTENANCE MANUAL
the full calibration position (up) for a (6). With reducer bushing removed from tee
minimum of 5 seconds. fitting, install an Oring on a suitable
airtight plug and tighten into tee
(b). Verify the the fuel quantity indicator fitting.
now reads approximately 759 pounds
(344.28 kg). (7). Bench test 600N8131 bypass pressure
switch as follows (denoted by six
(13). Place the BAT master switch to OFF housing screws):
position. Disconnect external power.
(a). Assemble test equipment shown in
2. Fuel Filter (Bypass) Caution Light Figure 501. Connect tester to pres-
Pressure Switch Test sure switch lead and connect ground
test lead to one of three screws on the
(Ref. Figure 501) housing body.
Air in the fuel system will (b). Remove reducer bushing and Oring
WARNING cause a power reduction or from switch. Wipe switch completely
flameout. Do a fuel system vacuum leak dry so any leakage can be detected
check and system air bleed after open- during the test.
prior to releasing helicopter for flight. (c). Apply 2.0 to 3.0 psig (13.8 20.68
Kpa) at port A .
NOTE: For all torques in the following proce-
dures, refer to Engine BuildUp, Section 1). There shall be no evidence of
710047. leakage. Replace a leaky switch.
(1). Set all switches; OFF. Disconnect 2). When air pressure is applied,
external electrical power. Disconnect switch shall be close when pres-
battery. sure at port A is 2.1 2.9 psid,
pound per square inch differential
(2). Open engine access doors. (4.3 5.9 in. Hg, inch of mercury).
(3). Locate pressure switch on engine fuel 3). When air pressure is bled off,
pump filter. Disconnect bypass switch switch shall be open when pres-
wire knife splice. sure at port A is 1.0 psid (2.0 in.
Hg).
CAUTION (d). Remove test equipment.
D Pressure switch is easily damaged. A (8). Remove plug from tee fitting. Install
slight shearing force applied to half the reducer bushing and bypass switch
pressure switch can cause leakage and, or assembly with new Orings on reducer
operational failure. Always grip both bushing and bypass switch. Torque
halves of pressure switch hex flats with switch assembly.
wrench when loosening or torquing at-
taching hardware. (9). Remove plug from bypass hose. Attach
hose to switch bushing. Torque hose
D Bypass pressure switch is not field repair- nut.
able. Do not disassemble switch. Return
faulty switches to vender for repair (Ref. (10). Install insulating sleeve and connect
Sec. 010000). switch wire knife splice.
(4). Disconnect hose from fuel filter pres- (11). Bleed fuel system.
sure switch. Install an airtight plug to
hose. (12). Operate engine per Pilots Flight
Manual and check fuel system for
(5). Remove fuel pressure switch with correct operation. Shut down engine.
reducer bushing. Inspect fuel system for leaks.
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Revision 22 280060
MAINTENANCE MANUAL
PRESSURE METHOD:
APPLY 23 PSIG (4.3 TO 5.9 IN HG) TO
PORT A THE SWITCH SHALL CLOSE.
BLEED OFF 1 PSIG (2.0 IN HG) THE
SWITCH SHALL OPEN.
HOSE
FUEL SWITCH
CEFA FILTER
PORT A
FUEL FILTER
PRESSURE SWITCH
NOTE
HOSE
OHMMETER
LOOKING FORWARD OR
CONTINUITY TESTER
PORT B
NOTE:
CONNECT GROUND TEST LEAD TO ONE OF SIX SCREW
HEADS ON THE HOUSING BODY. 6G28075
Figure 501. Fuel Filter Caution Light Pressure Switch Test Apparatus (C47 Engine)

280060 Revision 21
MAINTENANCE MANUAL
FUEL SYSTEM
INSPECTION/CHECK
2. Fuel Shutoff Valve Inspection
WARNING
(1). Shut down and disconnect all electrical
D Avoid fuel vapor ignition and fire. power.
Use only nonsparking tools and ex-
(a). In cargo/passenger compartment,
plosion proof work lights. Attach he-
open left aft fuel cell access panel.
licopter to an approved electrical
ground. Switch OFF all electrical (b). Disconnect fuel supply tube from fuel
power. Disconnect external power shutoff valve.
and battery before opening fuel sys-
tem. Ensure work area is adequately (c). Use an inspection mirror and flash-
ventilated. light to check shutoff valve ball
position.
D Air entering the airframe fuel supply
lines may cause a power reduction or (d). Ensure shutoff valve control knob is
flameout. Fuel system vacuum leak pushed in. Valve ball must be wide
check and fuel air bleed procedures open.
must be performed after opening fuel (e). Pull control knob out to stop. Valve
the supply system for any reason, ball should be closed.
prior to releasing helicopter for
flight. (2). Valves that can not be fully closed or
opened must be overhauled or replaced
prior to further flight.
1. Fuel System General Inspection
(3). Disconnect control cable from valve.
(1). Remove all fuel tank floor access (a). Inspect shutoff valve lever and cable
panels. swivel hardware for corrosion and
wear. Check lever for smooth move-
(2). Inspect fuselage bottom skin for ment from closed to open stops.
evidence of fuel leakage. No leaks
allowed. Determine source and repair (b). Use a spring scale to check tension
as required. required to move valve lever from full
open to closed. Design force require-
ment is 1.5 3.5 pounds (6.7 15.6
(3). Inspect fuel lines, fittings, cell access
N) maximum.
covers, fuel quantity unit, clamps and
attaching hardware for leakage, (c). Inspect valve for evidence of external
corrosion and security. Inspect fire leakage. External leakage not
sleeves for cuts, tears and punctures. allowed.
No leakage allowed. Repair or replace
components as required. (d). Check that lever detents at open and
closed positions. Repair or replace
valve as required.
(4). Inspect electrical wiring and connectors
for corrosion and security. Replace or (4). Connect and rig valve control cable.
repair wiring as required. Install cotter pin on cable swivel.
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280060 Revision 19
MAINTENANCE MANUAL
3. Tank Vent System Inspection hardware. Repair or replace vent

float/rollover valve as required.
WARNING and fire. Use only nonspark- 4. Fuel Quantity Probe Inspection
lights. Attach helicopter to an ap- (1). Inspect probe wire harness electrical
proved electrical ground. Switch OFF connector for serviceable conditional.
nal power and battery before opening (2). Inspect for bent or broken pins, frayed
fuel system. Ensure work area is ade- or broken wires. Repair or replace as
quately ventilated. required,
Prevent fuel system contamina- 5. Fuel System Vacuum Leak Inspection
hoses, tubes and fittings as parts are re- (Ref. Figure 601) Water, ice, dirt, fungus or a
moved. Bag and identify small parts to pre- few pinhole leaks in the supply system
vent loss or damage. between the fuel tank sump pickup and engine
driven fuel pump may cause power surges,
(1). Defuel helicopter. Drain remaining fuel deceleration and, or flameout. A vacuum leak
from tank sump drain valve into a inspection will determine whether or not air is
suitable container. being drawn into the engine fuel supply
system.
(3). Remove all four passenger/cargo access Special Tools
panels. (Ref. Section 910000)
Item Nomenclature
(4). Remove fuel vent cross over tube access
cover and disconnect hoses from ST801 Hand operated vacuum pump kit
forward vent crossover tubes.
(5). Blow lowpressure compressed air Air entering the airframe
through vent system to verify passages
WARNING fuel supply lines may cause
are clear. a power reduction or flameout. Fuel
system vacuum leak check and fuel air
(6). Check vent fairing passages for obstruc- bleed procedures must be performed
tions and condition. Repair or replace after opening the fuel supply system
fairings as required. for any reason, prior to releasing heli-
copter for flight.
(7). Inspect vent system hoses for deteriora-
tion. Pinch or bend hoses and look for (1). Remove left fuel cell floor access panel.
surface cracks. Replace hose if cracks
are apparent. (2). Pull FUEL shutoff valve knob out to
stop. Verify that fuel shutoff valve lever
(8). Inspect vent tubes for dents, cracks, is hard against its OFF stop.
deformation or corrosion. Smooth
nonrestrictive dents are permissible (3). In engine compartment; remove and
except at lower vent end which must fit plug the motive fuel line at the CEFA.
flush within vent fairing flared riser.
(4). Assemble vacuum pump (ST801) hoses,
(9). Inspect crossover fittings for cracks, filter port adapter, shutoff valve and
dents or corrosion. Smooth nonrestric- vacuum gauge.
tive dents are permissible.
(a). Install the vacuum gauge in the line
(10). Inspect fuel vent float/rollover valves between the filter port adapter and
for serviceable condition, leakage and shutoff valve. Attach the vacuum
corrosion. Inspect for loose or missing pump above the shutoff valve.
Page 602
Revision 31 280060
MAINTENANCE MANUAL
MOTIVE FUEL LINE

FUEL FILTER UPPER
DRAIN PORT FUEL FILTER OIL FILTER
VACUUM GAGE
SHUTOFF VALVE
FUEL IN PORT
VACUUM
PUMP OIL OUT PORT
TEE FITTING
FUEL OUT PORT
FILTER PORT ADAPTER OIL IN PORT

6G28077
Figure 601. Fuel System Vacuum Leak Inspection

(5). Attach vacuum test pump to engine fuel The fuel shutoff and drain valve
filter upper drain port. Apply 8.0 Hg installations should be especially
vacuum. Close vacuum line shutoff suspect. Apply vacuum at each stage
valve. until leak has been isolated. Replace
parts as required.
(6). Fuel system shall hold vacuum between
8.0 and 7.5 Hg for two minutes. NOTE: If the vacuum held at 7.5 Hg or better,
airframe system seal is satisfactory and
(7). If test is satisfactory, remove test leak is due to an engine fuel system prob-
vacuum. lem. Refer to the applicable Allison and Ben-
(8). Reconnect and torque the fuel vapor dix manuals for additional information.
return line.
(11). Apply a torque stripe to all effected fuel
NOTE: Vacuum loss exceeding 0.5 Hg in two line fittings and nuts.
minutes indicates a leak in the system be-
tween, and including, the fuel shutoff valve 6. Drain Valve Inspection
and engine.
(9). Retorque fuel line connections and WARNING cause a power reduction or
where installed, antiice (airframe) fuel flameout. Do a fuel system vacuum leak
filter fittings and line nuts (Ref. Sec. check and fuel system air bleed after
282500). Repeat vacuum test. opening fuel system to atmosphere and
(10). If system continues to leak, disconnect
and install airtight caps on lines and (1). Inspect tank sump drain valves for
fitting ports in a progressive sequence leakage and security. No leakage
from fuel shutoff valve toward engine. allowed. Replace valve as required.
Page 603
280060 Revision 31
MAINTENANCE MANUAL
7. Fuel Cell Inspection 8. Fuel Cell Leak Inspection
CAUTION (Ref. Section 910000)
Item Nomenclature
N/A Ammonia
D Do not work on Engineered Fabric Corp.
N/A Cloth, cotton flannel
fuel cell in ambient temperatures below
N/A Phenolphthalein, crystalline
70F (21C).
CM218 Alcohol, denatured
D Do not remove fuel cells unless absolutely CM810 Leak detector, liquid
required. CM820 Cheesecloth
D The barrier can be invisibly torn, punc- Any one of three techniques can be used to find
tured or cracked by careless handling. leaks in nonselfsealing and selfsealing fuel
cells. The methods are listed in ascending
D Do not carry or move cell by its metal fit- order of effectiveness and complexity in terms
tings. of required equipment, materials, time, and
effort.
D Never probe cell material with sharp
edged or pointed tools. Soap bubble leak inspection.
Phenolphthalein stain inspection.
NOTE: Liquid stand inspection.
D Nonselfsealing and selfsealing cells

NOTE: The soap bubble and phenolphthalein
inspections require the cell to be inflated
are primarily a 0.002 inch (0.051 mm) with air.
thick nylon barrier membrane sand-
wiched between lightweight construc- (1). Manufacture or supply the following
tions of either rubberized (Uniroyal) or equipment necessary to do soap bubble
plasticized (Engineered Fabrics Corp.) or phenolphthalein inspections:
nylon fabric that protects and strength- (a). Rigid, airtight closures or plugs to
ens the barrier. seal all cell openings. Fit one cover
plate with:
D Selfsealing cells may have one or more
thin layers of natural rubber sandwiched (b). An air pressurization inlet fitting.
between the barrier and fabric plies. (c). A manometer or an extremely
accurate and sensitive low pressure
air gauge.
(1). Apply protective tape to all machined
metal fittings. A. Soap Bubble Leak Test Procedures
NOTE: Soap bubble test reliability is good for
bladder type nonselfsealing cells.
(2). Perform cell inspection on a padded,
clean, craft paper covered surface. (1). Remove cell from helicopter.
(2). Lay cell out on a padded table. Install
cell closures.
(3). Inspect fuel cells per applicable man-
ufacturers requirements (Ref. Sec. (3). Inflate cell to 1/4 psi (1.7 kPa), maxi-
010000). mum.
Page 604
Revision 31 280060
MAINTENANCE MANUAL
(4). Unless leak is immediately evident, (f). Inspect the entire exterior surface of
maintain 1/4 psi (1.7 kPa) pressure for the cell.
two hours to allow any air trapped in
cell exterior laps and seams to escape. (5). Repair cell as required.
(5). Run soap solution around all patches, C. Liquid Stand Inspection
lap joints, seams, fittings, creases, (1). Remove cell from helicopter and place
abrasions and any other suspicious on a clean, padded, kraft paper covered
areas. Bubbles will appear over a leak. table.
(6). Mark leak areas with a white or yellow (2). Fabricate closure plates for each cell
crayon. opening.
(7). Repair cell as required. (a). The object is to completely fill the cell
B. Phenolphthalein Stain Inspection and eliminate all air pockets. Equip
Procedures one of the plates with liquid filler and
vent stand pipes at least six inches
(1). Remove cell from helicopter. (15 cm) tall.
(2). Lay cell out on a padded table. Install (b). Fill the cell with Stoddard solvent,
all but one of the cell closures. Stanisol or Varsoline.
(3). Make phenolphthalein solution as (c). Permit cell to stand undisturbed for
follows: 24 hours.
(a). Add 40 grams phenolphthalein (d). Inspect paper to determine where cell
crystals to 1/2 gallon (1.9 L) of is leaking.
denatured alcohol (CM218) and stir. (e). Change paper as required. Drain,
(b). Add 1/2 gallon (1.9 L) of water. Allow turn over, refill and let cell stand for
to stand 30 minutes. Stir before another 24 hours to ensure liquid has
using. contacted all cell surfaces.
(4). Pour commercial ammonia on an (f). Repair cell as required.

absorbent cloth in a ratio of one
9. Fuel Tank Pressure Leak Test
teaspoon (3 ml) per cubic foot of cell
capacity (minimum of 10 ml or 3.3
teaspoons). Special Tools
(a). Place the ammonia saturated cloth Item Nomenclature
inside the cell and install the remain-
N/A Manometer
ing cover.
(b). Inflate cell with air to 1/4 psi (1.7 NOTE: Always test and inspect a repaired fuel
kPa) maximum. Maintain 1/4 psi (1.7 cell for leaks using soap bubble, phenolph-
kPa) pressure for 15 minutes mini- thalein or liquid stand method before in-
mum, before proceeding. stalling the cell in the helicopter.
(c). Soak a large white cloth in the (1). Use the following procedures to check
phenolphthalein solution. Thoroughly installed fuel tanks and plumbing for
wring cloth out. leaks.
(d). Spread and smooth cloth onto cell. Do (a). Plug vent system.
not let cloth dry out.
(b). Remove cell floor access panels.
(e). A red spot will appear on the cloth
where there is a leak in the cell wall. (c). Install manometer and air pressur-
Mark each leak. ization equipment.
Page 605
280060 Revision 31
MAINTENANCE MANUAL
(d). Apply 2 psi (14 kPa) air pressure for

10 minutes to precondition cells. This WARNING
forces trapped air from between fuel
cells and helicopter structure. If D Avoid fuel vapor ignition and fire.
necessary, repeat until cells adjust to Use only nonsparking tools and ex-
contour of cell bay. plosion proof work lights. Attach he-
licopter to an approved electrical
(e). Apply 2 psi (14 kPa) air pressure for
ground. Switch OFF all electrical
15 minutes with no visible, less than
1/4 inch (6.35 mm), drop on manome- power. Disconnect external power
ter. If pressure drop occurs, check all and battery before opening fuel sys-
vent plugs, fittings and retest cells. tem. Ensure work area is adequately
Repair or replace parts as necessary ventilated.
to eliminate pressure drop.
D Engine operation or helicopter flight
(f). Unplug vent system. Remove ma- must be accomplished in accordance
nometer and pressurization equip- with requirements and limitations
ment. specified in the 600N Rotorcraft
(g). Install cell floor access panels. Flight Manual and applicable sup-
plements.
10. Fuel Transfer System Functional Check
NOTE: This check is only done on aircraft Prevent fuel system contamina-
without the airframe fuel filter option. CAUTION tion. Install caps on the ends of
(Ref. Figure 602) hoses, tubes and fittings as parts are re-
Special Tools vent loss or damage.
Item Nomenclature NOTE: Gross weight, fuel load and ambient
ST803 Fuel Transfer System Functional Tester conditions are optional for this functional
check.
FUEL PRESSURE
SWITCH HOSE
FUEL PRESSURE SWITCH
UNION
CEFA BEFORE FILTER
CEFA PORT
MOTIVE FLOW
SUPPLY HOSE
LOOKING FORWARD 6G28078
Figure 602. Fuel Transfer System Functional Check
Page 606
Revision 43 280060
MAINTENANCE MANUAL
A. Test Setup
(Ref. Figure 602 and Figure 603)
CEFA
TESTER INLET A
LINE
TESTER INLET
LINE
TESTER OUTLET
LINE FLOW METER
MOTIVE FLOW
SUPPLY HOSE
6G28079
Figure 603. Fuel Transfer Test Setup
Page 607
280060 Revision 43
MAINTENANCE MANUAL
(1). Make sure fuel transfer system tester lective to increase N1 speed. Reduce throttle
calibration is current. twist grip to decrease N1 speed.
(2). Disconnect motive flow supply hose (5). Record N1, pressure altitude, outside
from CEFA before filter port union. air temperature, motive flow rate and
motive flow pressure.
(3). Connect inlet line of tester to CEFA
before filter port union. (6). Use the calibration chart provided with
the fuel transfer system tester and
(4). Torque tester fitting to 50 65 inch calculate the calibrated motive flow
pounds (5.64 7.34 Nm). rate.
(5). Connect motive flow supply hose to (7). The minimum calibrated motive flow
outlet line of tester. rate shall be 0.18 GPM.
(8). If the calibrated motive flow rate is less
(6). Torque motive flow supply hose fitting
than 0.18 GPM, check the following
components for correct operation.
Nm).
(a). Check valve
B. Check Procedures
(b). Jet (ejector) pump
(c). Motive flow hoses
(1). Make sure test setup is complete.
(9). Shut down engine ground run in
(2). Ground run engine in accordance with accordance with Rotorcraft Flight
Rotorcraft Flight Manual. Manual.
(3). Operate the helicopter on the ground at (10). Disconnect motive flow supply hose
100 percent main rotor speed (Nr) with from outlet line of tester.
collective down. (11). Disconnect inlet line of tester from
CEFA before filter port union.
(4). Stabilize motive flow pressure from
42.0 PSIG minimum to 44.0 PSIG (12). Connect motive flow supply hose to
maximum. N1 at approximately 81 CEFA before filter port union.
percent.
(13). Torque motive flow supply hose fitting
NOTE: Motive flow pressure increases or de- to 50 65 inchpounds (5.64 7.34
creases with engine N1 speed. Increase col- Nm).
Page 608
Revision 43 280060
MAINTENANCE MANUAL
FUEL SYSTEM
REPAIRS
1. Fuel Shutoff Valve Control Cable Repair NOTE: MDHS cannot guarantee the currency,
completeness or technical accuracy of fuel
cell repair procedures provided herein.
Consumable Materials Since cell repair materials, techniques, and
(Ref. Section 910000) procedures may be changed or deleted by
Item Nomenclature the cell manufacturers without notice to
CM118 Grease MDHS light helicopter publications; we
strongly recommend that:
NOTE: Worn fuel shutoff valve control cables (1). Only specially trained personnel are
are normally replaced as an assembly. allowed to inspect and repair the fuel
cells installed in 369/500/600 series
(1). The only authorized repair is replace- helicopters.
ment of a missing detent ball, as
follows: (2). Customers planning to do their own
fuel cell repairs must order any re-
(a). Disconnect cable from fuel shutoff quired manuals from the applicable cell
valve lever swivel. manufacturer before beginning repair
tasks (Ref. Sec. 010000).
(b). Pull plunger out until detent ball (a). Cell inspections, maintenance and
hole is visible. Insert detent release repair must be per the cell manufac-
rod in plunger. Align notch in detent turers advice and instructions.
release rod with plunger detent ball
hole. (3). Bladder or self sealing fuel cells are
supplied to MDHS by Engineered
(c). Apply grease (CM118) between Fabrics Corporation.
plunger and plunger housing.
Use only approved inspection
(d). Insert detent ball in plunger hole.
CAUTION requirements, repair methods,
Push release rod and plunger to full materials and supplies designed for Engine-
open position. ered Fabrics Corp.
(e). Rig fuel shutoff valve cable. (4). Fuel cells produced by Engineered
Fabrics Corp. are constructed of Nitrile
polyurethane plastic impregnated
2. Fuel Cell Repair
fabric.
Consumable Materials 3. Scuff Mark Repair

Fabric exposed by a scuff mark may be buffed,
Item Nomenclature
cleaned, coated with cement and allowed to
CM219 Methylethylketone airdry for 8 hours. No patch is required
CM603 Patching material unless fabric is torn. Install patches where
CM604 Patching material required (Ref. Patch Installation).
CM605 Fuel cell repair kit 4. Reinforcements, Hangers and Splice
CM607 Cement Repairs
Loose reinforcement edges, hangers or lap
CM820 Cheesecloth splices must be lifted, buffed, cleaned, cem-
N/A Polyethylene plastic, sheet or roll ented and cured under pressure per applicable
instructions (Ref. Patch Installation).
Page 801
280060 Revision 19
MAINTENANCE MANUAL
5. Loose Patch Repair (b). Use a greaseless silver pencil to

outline patch installation area two
Replace loose patches with new patch installa- inches beyond damage in all direc-
tions (Ref. Patch Installation). Where two tions.
opposing patches have been installed over cell
wall damage, unless otherwise indicated by (6). Handbuff an area 1/2 inch (12.7 mm)
inspection, replace only the loose patch. larger than space occupied by patch
with fine emery cloth (CM804) to
provide a roughened substrate for
6. Patch Installation cement application. Do not cut through
cell fabric.
(1). Drain, remove and thoroughly dry cell
as soon as possible after determining (7). Select a patch of #5218 material
cell repair is required. Drying time may (CM604) for cell exterior. Trim patch to
be accelerated by keeping cell at 80F extend two inches beyond edges and
(27C) and ventilating interior with dry, ends of damage in all directions. Tilt
low pressure air. scissors to bevel patch edges away from
cell surface. Radius all patch corners.
(2). Inspect fuel cell.
(8). Handbuff patch gummed surface with
Do not repair tears or holes over fine emery cloth. Ensure entire patch
CAUTION two inches (5.08 cm) long using joint surface has been abraded.
cold patch repair. Do not attempt to repair
(9). Repeat buffing procedures on cell
bonded fittings or corners. Contact Engine-
interior surface. Buff internal patch
ered Fabrics Corporation when corner or fit-
(CM603) trimmed from
ting damage is discovered or when cell wall
#5200/5187/5194 sandwich material.
damage exceeds two inch length limit.
Fuel cell and patch contact sur-
(3). Accomplish fuel cell repair work in CAUTION faces must be perfectly clean
temperatures ranging from 60 80F and dry prior to adhesive and patch applica-
(16 27C) and in less than 50% tion. Rubber and fabric particles, moisture,
humidity. and fuel or oil from fingers will prevent
proper patch/cell adhesive cure and may
NOTE: Damp air, especially in combination subsequently provide a leak path. Wear
with low temperatures, will cause water to clean, lint free gloves to handle patch and
condense on cement applications. Water in- cell after preparing surfaces for cement and
hibits patch adhesion. patch application.
Never expose a dry cell to high (10). Install exterior patch first. Wipe cell
CAUTION temperatures and, or direct sun- exterior and patch faying surfaces with
light for long periods of time. If repairs will clean cheesecloth (CM820) dampened
not be started within ten days, prepare cell with MEK (CM219).
for storage.
(a). Continue to wipe cell and patch,
(4). Both sides of a cell must be patched to changing cheesecloth and applying
repair any one hole or tear. clean solvent as required, until no
stain or particles appear on cheese-
cloth pad after the last wipe.
(5). Thoroughly clean cell internal and
external repair areas with cheese cloth Use cement sparingly. Two,
(CM820) dampened with solvent MEK CAUTION thin, even coats provide better
(CM219). adhesion than one thick coat.
(a). Collapse cell and expose external (11). Position a sheet of polyethylene plastic
damage area on a clean, flat working beneath cell damage to keep cement off
surface. opposite cell wall.
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MAINTENANCE MANUAL
NOTE: Determine cement adhesive tack with a Plates must be larger than cemented
test specimen. Apply cement to a piece of repair area.
buffed, scrap patch material each time ce-
ment is spread on cell and repair patch. Excessive clamp pressure may
(12). Coat patch, test specimen, and fuel cell, ment out of joint.
including edges of damage, with EC678
cement (CM607). Allow cement to dry (a). Cover both sides of repair with sheet
15 minutes before application of a polyethylene plastic or oiled paper
second coat. Allow second coat to dry 15 large enough to cover entire cem-
minutes. ented area.
(13). Press a bare knuckle into cement on NOTE: Do not include opposite cell wall in
test specimen. Cement that tears away clamp up. Work through cell access opening
from skin leaving a rough, finely and arrange cell as necessary to clamp only
peaked imprint without transferring to the wall with the patch installation.
knuckle, is ready for patch installation.
(b). Sandwich repair area and barrier
NOTE: Wipe cement with cheesecloth moist- material between pressure plates.
ened with solvent to reactivate adhesive Install at least two Cclamps over
when required. pressure plates. Equalize clamp
pressure.
(14). A brayer or similar tool is required to
systematically roll patch into contact (16). Do not disturb cell. Maintain pressure
with cell. Apply patch as follows: for six hours, minimum, after which cell
is ready for internal patch installation.
(a). Center patch on repair area. Stick
one edge down and double check (17). Remove clamps and plates.
patch alignment. If required, release (18). Clean patch and cell internal repair
adhesive by flooding joint with area with MEK saturated cheesecloth
solvent. Check adhesive tack again swabs.
before proceeding with patch installa-
tion. (a). Apply two coats of cement, allowing
15 minutes drying time between
NOTE: The object of the next step is to get the coats. Allow 15 minutes for second
patch down without trapping any air under coat to set.
it.
(b). Install and roll out patch.
(b). Hold free edge of patch off cell.
Follow one line and roll tool back (19). Position a barrier sheet under each
andforth over patch. Advance pressure plate. Clamp and cure instal-
toward loose end, 1/4 inch (6.35 mm) lation for a minimum of 24 hours at 60
per pass until patch is down and free 80F (16 27C) before leak testing
of trapped air. and returning cell to service.
(c). An alternate technique is to lay 7. Loose Edge and Lap Seam Repairs
prepared patch on a perfectly clean
sheet of polyethylene plastic about Loose lap seams should be re-
twice the size of the patch. Locate CAUTION paired as soon as possible after
plastic sheet and patch over cell discovery.
repair area; then, slip sheet from
under patch as patch is rolled down, NOTE: Loose lap seam edges not more than two
1/4 inch (6.35 mm) at a time. inches long on cell interior or exterior sur-
faces may be repaired. Seam separation re-
(15). Fabricate two smooth, flat, rigid, metal pairs require buffing, cementing and a
plates with no sharp edges or corners. patch installation.
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MAINTENANCE MANUAL
(1). Lift seam separation and buff flap and (f). Cover repair with a sheet of polyeth-
cell faying surfaces with emery cloth ylene plastic or oiled paper large
(CM804). enough to cover entire cemented
area.
(a). Buff an area on exterior surface
extending 2 inches (5.08 cm) in all (2). Fabricate two smooth, flat, rigid, metal
directions from seam separation. plates with no sharp edges or corners.
Plates must be larger than cemented
repair area.
CAUTION
D Fuel cell and patch contact surfaces must CAUTION deform cell and, or squeeze ce-
be perfectly clean and dry prior to adhe- ment out of joint.
sive and patch application. Rubber and
fabric particles, moisture, and fuel or oil (a). Cover both sides of repair with
from fingers will prevent proper patch/ polyethylene plastic or oiled paper
cell adhesive seal and may subsequently sheets large enough to cover entire
provide a leak path. Wear clean, lint free cemented area.
gloves to handle patch and cell after pre-
paring surfaces for cement and patch NOTE: Do not include opposite cell wall in
application. clamp up. Work through cell access opening
and arrange cell as necessary to clamp only
D Careless application of compressed air be- the wall containing the seam repair.
tween lap joints may separate seam fur-
ther. (3). Sandwich cell wall repair area and
barrier material between pressure
(b). Either airvacuum or blow buffing plates. Install at least two Cclamps
dust out of separation with dry, low over pressure plates. Equalize clamp
pressure, compressed air. pressure.
(c). Wipe inside and outside of repair (4). Do not disturb cell. Maintain pressure
area clean with cheesecloth (CM820) for six hours, minimum, after which cell
moistened with MEK (CM219). is ready for patch installation.
Continue wiping with fresh solvent
dampened cheesecloth as required (a). Remove clamps and plates.
until no stain or particle appears on (5). Use #5200/5187/5194 sandwich patch
the swab after the last wipe. Allow material on cell interiors.
area to dry.
(6). Use #5218 patch material on cell
Use cement sparingly. Two thin, exterior surfaces.
CAUTION even coats provide better adhe-
sion than one thick coat. (7). Prepare cell wall and patch for installa-
tion per (Ref. Patch Installation):
NOTE: Determine cement adhesive tack with a Install patch.
test specimen. Apply cement to a piece of
buffed, scrap patch material each time ce- 8. Blister Repair
ment is spread on cell and repair patch. Blisters can occur on cell interior and exterior
surfaces. blisters are caused by a separation of
(d). Apply two coats of EC678 cement
the cell laminates and may contain air or a
(CM607) allowing 15 minutes be-
combination of air and fuel.
tween applications. Allow second coat
to dry 15 minutes. NOTE: Exterior blisters that contain fuel indi-
cate that the barrier has been penetrated.
(e). Roll separation together starting Blisters inside cell measuring under one
from the bottom of the pocket toward inch diameter are acceptable and need not
the open end, 1/4 inch (6.35 mm) per be disturbed.
pass. Ensure no air is trapped
underneath. (1). Repair blisters as follows:
Page 804
Revision 19 280060
MAINTENANCE MANUAL
(a). Buff surface of blister and area (2). Fabricate two smooth, flat, rigid, metal
extending two inches (5.08 cm) in all plates with no sharp edges or corners.
directions from its edge. Plates must be larger than cemented
repair area.
Avoid damaging nylon barrier
CAUTION membrane. Do not probe, cut, or Excessive clamp pressure may
puncture blisters with tool perpendicular to
cell wall. ment out of joint.
(b). Slit blister open with an X cut to (a). Cover both sides of repair with
expose all of the delaminated surface. polyethylene plastic or oiled paper
Lift flaps and mop interior with clean sheets large enough to cover entire
cheesecloth (CM820) and MEK cemented area.
(CM219). Buff underlying cell surface NOTE: Do not include opposite cell wall in
and blister flaps with emery cloth clamp up. Work through cell access opening
(CM804). Airvacuum or blow away and arrange cell as necessary to clamp only
all traces of buffing dust. the wall containing the blister repair.
(c). Wipe inside and outside of repair (3). Sandwich cell wall repair area and
area clean with cheesecloth moist- barrier material between pressure
ened with solvent or MEK. Continue plates. Install at least two Cclamps
wiping with fresh solvent dampened over pressure plates. Equalize clamp
cheesecloth as required until no stain pressure.
or particle appears on the swab after
the last wipe. Allow area to dry. (4). Do not disturb cell. Maintain pressure
for six hours, minimum, after which cell
Use cement sparingly. Two, is ready for patch installation; remove
CAUTION thin, even coats provide better clamps and plates.
(5). Use #5200/5187/5194 sandwich patch
NOTE: Determine cement adhesive tack with a material on cell interiors.
test specimen. Apply cement to a piece of (6). Use #5218 patch material on nonself
buffed, scrap patch material each time ce- sealing cell exterior surfaces.
ment is spread on cell and repair patch.
(7). Prepare cell wall and patch for installa-
(d). Apply two coats of EC678 cement tion per instructions for Patch Installa-
allowing 15 minutes between application. Install patch.
tions. Allow second coat to dry 15
minutes. (8). Heat soak transmitter assembly in an
oven set at 100F (38C), maximum for
(e). Roll blister together starting from the one hour to vaporize trapped volatiles.
bottom of each flap pocket toward the A heat gun may be used as an alternate
open end, 1/4 inch (6.35 mm) per drying method. Pot transmitter electri-
pass. Ensure no air is trapped cal connections with sealing compound
underneath. MILS8802 (CM425).

280060 Revision 19
MAINTENANCE MANUAL
Section
282500
AntiIce / Airframe
Fuel Filter (369D/E
500/600N)
MAINTENANCE MANUAL

MAINTENANCE MANUAL
ANTIICE/AIRFRAME FUEL FILTER

Table 1. AntiIce/Airframe Fuel Filter Effectivity
Installation Model & Production Number Features
369H90022BSC 369D, 003 and subsequent Helicopters equipped with slimline instrument panel.
369H90022503 369E, 001 and subsequent Helicopters equipped with Tinstrument panel.
369H90022503 500N, 001 and subsequent Helicopters equipped with Tinstrument panel.
600N98110501 600N, 003 and subsequent Helicopters equipped with Tinstrument panel.
NOTE: Antiice / airframe fuel filter is not certified for installation on C30 engine installation.
NOTE: On the 600N helicopter, the airframe pilot of an impending or total fuel filter
fuel filter is not certified as an antiice fuel blockage by lighting the AIRFRAME
filter. Throughout this section, the airframe FILTER caution lamp in the caution/
fuel filter will be refered to as an antiice warning panel. The pilot must manual-
fuel filter. ly set the START PUMP switch ON to
pressurize the fuel system.
1. Description
(4). On all installations, total filter blockage
(1). The airframe mounted antiice fuel forces a filter bypass valve in the filter
filter is installed on the aft face of the body open to second supply unfiltered
firewall upstream of the engine fuel fuel to the engine.
pump filter. The 10 micron, 500 square
inch disposable filter element strips ice (5). Pressing the FUEL FILTER caution
and other solids from the fuel before it light/switch supplied with
enters the engine fuel system. 369H90022BSC installations resets
relay K254 and the time delay relay,
2. Operation shuts down the start pump and START
PUMP ON light and switches off the
(1). A flow pressure sensing switch in the FUEL FILTER caution light.
filter body furnished with all installa-
tions closes when flow differential (6). The caution light dimmer switch on the
pressure across the filter drops to a lower left control panel of BSC
preset level. installations controls only FUEL
FILTER caution light intensity with
(2). On the 369H90022BSC installation, DIM or BRT positions. FUEL FILTER
pressure switch contact closure directs caution lamp test is executed with the
28Vdc current across the S2 contacts of PRESS TO TST WARN LT switch on
the FUEL FILTER relay K254 to the caution/warning light panel.
activate the RT170277 time delay
relay (TDR). The TDR energizes relay (7). On 503, 505 and 501 installations,
K254 after a two to five second delay, caution light intensities, including the
closing switches S1, S2, and S3; AIRFRAME FILTER light are
energizing the FUEL FILTER caution controlled through the WARN LT DIM
light, start pump and START PUMP potentiometer on the pedestal switch
ON light. panel.
(3). On 369H90022503, 505 and (8). Circuit protection is provided by the 7.5
600N98110501 fuel filter installations, ampere antiice FUEL FILTER circuit
pressure switch closure only advises the breaker on the antiice fuel filter panel.
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282500 Revision 39
MAINTENANCE MANUAL
Determine why a circuit break- Air in the fuel system will

CAUTION er popped before pushing the re- WARNING cause a power reduction or
set button (Ref. Table 101). flameout. Do a fuel system vacuum leak
(9). A presstotest button located on top of
the filter body is featured in all installa-
tions. Pressing the button simulates a
Ensure start/boost pump is operating
blocked filter condition for poweron
ground test. before taking fuel samples from system
drain valves.
(10). On all installations, a filter bowl drain
valve plumbed into the drain manifold
provides for filter draining and fuel (11). Refer to Table 101 for antiice fuel filter
sampling. fault isolation information.
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Revision 20 282500
MAINTENANCE MANUAL

FAULT ISOLATION
NOTE: On the 600N helicopter, the airframe
fuel filter is not certified as an antiice fuel
filter. Throughout this section, the airframe
fuel filter will be refered to as an antiice
fuel filter.
1. AntiIce Fuel Filter System Fault Isolation
Table 101. AntiIce Fuel Filter System Fault Isolation
FUEL FILTER caution lamp No power. Battery switch OFF. Supply power. Set battery switch to BATT or
does not light. EXT PWR position.
Circuit breaker reset button Press circuit breaker reset button.
pulled out. (369D/E 500N)
Defective wiring or connection. Locate circuit defect and repair as required.
FUEL FILTER caution light on. System not reset. Press FUEL FILTER caution light to reset.
Clogged fuel filter. Drain filter bowl into a suitable container.
Inspect sample for foreign substances.
Remove and replace filter element.
Defective wiring. Locate circuit defect and repair as required.
START PUMP ON lamp fails No power. Battery switch OFF. Supply power. Set battery switch to BATT or
to light. EXT PWR.
Circuit breaker reset button Press circuit breaker reset button.
pulled out. (369D/E 500N)
Defective lamp. Replace lamp.
Defective wiring. Locate circuit defect and repair as required.

282500 Revision 20
MAINTENANCE MANUAL

NOTE: On the 600N helicopter, the airframe B. AntiIce Fuel Filter Installation
fuel filter is not certified as an antiice fuel
fuel filter will be refered to as an antiice Consumable Materials
fuel filter. (Ref. Section 910000)
Item Nomenclature
CM113 Antiseize compound low temperature
1. AntiIce Fuel Filter Replacement
(Ref. Figure 201) (1). Attach assembled filter to bracket with

bolts, washers and spacers. Torque
A. AntiIce Fuel Filter Removal bolts 50 70 inchpounds (5.65 7.91
Nm). Install lockwire.
Prevent fuel vapor ignition.
WARNING Turn OFF and disconnect all (a). Apply a thin coat of antiseize
electrical power. Electrically ground compound (CM113) to all male fuel
helicopter before opening fuel system. line fittings.
Do not twist hoses while torqu-

(1). Disconnect battery and external power CAUTION ing hose nuts. Use a backup
(Ref. Sec. 960510). wrench to stabilize hose.
(a). Pull FUEL VALVE knob to close fuel (b). Install hose between filter and
shut off valve. engine. Install hose between filter
and firewall fitting. Torque hose nuts
(b). Open engine access doors. 230 260 inchpounds (25.99
29.38 Nm).
(c). Drain fuel from filter bowl and
supply line drain valves. (c). Connect wire harness connector to
fuel filter plug.
(d). Unclamp and disconnect filter drain (d). Connect drain tube to filter drain
tube. valve. Clamp tube to valve with
lockwire.
(e). Remove fuel supply hose between
engine driven fuel pump and antiice Air in the fuel system will
filter. Cap hose ends and fittings. WARNING cause a power reduction or
(f). Remove hose assembly between check and system air bleed after open-
antiice filter and firewall fitting. ing fuel system to atmosphere and
Cap hose ends and fittings. prior to releasing helicopter for flight.
Ensure start pump is operating before
(g). Remove antiice filter electrical taking fuel samples from system drain
connector. valves.
(e). Perform a fuel system vacuum leak

(h). Unbolt and remove filter body check (Ref. Fuel System Vacuum
assembly. Leak Check).
(i). Unscrew filter bowl from body, as (f). Bleed fuel system (Ref. Fuel System
required. Air Bleed).
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282500 Revision 20
MAINTENANCE MANUAL
2. Fuel System Air Bleed (d). Set helicopter master switch to

BATT.
Prevent fuel vapor accumu-
WARNING lation, ignition and fire. Per- (e). Set START PUMP switch ON to
form work in an open, well ventilated pressurize fuel system. Check start
area away from all potential ignition pump for operation.
sources. Attach helicopter to an ap-
(f). Loosen engine filter bowl plug. Let
proved electrical ground. Wear ap-
fuel flow until a steady, bubble free,
proved eye protection.
uninterrupted fuel stream emerges
Do not operate start pump in an without any evidence of trapped air.
CAUTION empty fuel tank. Tighten plug.
(2). Refer to applicable Allison Engine
NOTE: The object of fuel system bleeding is to Operation and Maintenance Manual for
remove all air trapped in the fuel supply specific engine fuel system air bleed
system. information.
(1). Refuel helicopter as required. (a). Purge air from engine fuel system
per Allison Engine Operation and
(a). Connect battery. Maintenance Manual.
(b). Open engine access doors. (3). Set START PUMP and battery
switches OFF.
(c). In crew compartment; push FUEL
shutoff valve knob in to open shutoff (4). Reassemble drain system as required
valve. and install lockwire.
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Revision 20 282500
MAINTENANCE MANUAL
BOLT
CONNECTOR
WASHER
TEST
CLAMP BUTTON
NUT
NUT
BRACKET
ORING
SCREW
REDUCER
CLAMP FIREWALL
WASHER
WASHER SCREW
NUT HOSE
FILTER TUBE
ELEMENT
WIRE BOWL NUT
HARNESS
SHIM WASHER
(AS REQD)
GASKET
WASHER
NUT FITTING
WASHER HOSE
ORING HOSE
ELBOW
CLAMP
SCREW SCREW
GASKET
CLAMP
ANTIICE WASHER
DRAIN VALVE NUT
BOLT
EFFECTIVITY: 369D/E 500N G2820001B
Figure 201. AntiIce Fuel Filter (Sheet 1 of 3)
Page 203
282500 Revision 19
MAINTENANCE MANUAL
CAUTION LIGHT
TPEDESTAL
(369H90022503, 505)
ANTI ICE
FUEL FILTER
INSTL
FOR
PLACARD SPACER
WASHER
SCREW
SCREW RIVNUT
DIODE CR26
TIMEDELAY
RELAY
CAUTION LIGHT/
RELAY K254
CIRCUIT BREAKER
DIMMER SWITCH
SCREW
COVER
SCREW SLIMLINE PEDESTAL
(369H90022BSC)
EFFECTIVITY: 369D/E 500N G2820002A
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Revision 19 282500
MAINTENANCE MANUAL
B
A
B
FUEL HOSE
TO ENGINE
FUEL HOSE FROM

ENGINETOTANK
CONNECTOR +
CLAMP
SCREW
WASHER
NUT
REDUCER
ORING
FUEL HOSE
FROM TANK
FILTER
DRAIN VALVE
FUEL FILTER
DRAIN HOSE
GROMMET
VIEW A A
AIRFRAME FILTER
CAUTION LIGHT
VIEW B B
EFFECTIVITY: 600N G2820003

282500 Revision 19
MAINTENANCE MANUAL

INSPECTION/CHECK
NOTE: On the 600N helicopter, the airframe (g). Do an antiice fuel filter functional
fuel filter is not certified as an antiice fuel check (Ref. AntiIce Fuel Filter
filter. Throughout this section, the airframe Installation Operational Check:
fuel filter will be refered to as an antiice 369H90022BSC).
fuel filter.
(2). Inspect wiring for damage and security.
1. AntiIce Fuel Filter System Inspection Repair or replace damaged components.
A one time diode inspection and WARNING cause a power reduction or
CAUTION polarity check is mandatory for
helicopters equipped with a
369H90022BSC antiice fuel filter instal-
lation and, or 369H90118 autoreignition
installation on helicopters delivered in
Ensure start pump is operating before
1979. The following procedures address only
taking fuel samples from system drain
the antiice fuel filter installation.
valves.
Special Tools (3). Inspect fuel system as follows:

(Ref. Section 910000) (a). Apply external power to the helicop-
Item Nomenclature ter.
N/A Ohmmeter (b). Open the engine compartment doors.
N/A Voltmeter
(c). Set battery switch to EXT PWR.
(1). Determine ohmmeter lead polarity with (d). Push FUEL VALVE knob in to open
voltmeter. fuel shutoff valve.
(e). Set START PUMP switch; ON.
(a). In crew compartment; remove cover
Check start pump operation.
from antiice caution/warning light
panel. NOTE: Failure to drain in freezing tempera-
tures may be due to ice buildup.
(b). Find part number stamped on diode
C26 (Ref. Figure 201). (f). Drain several ounces of fuel from
filter bowl into a suitable container.
(c). Diodes, part numbers 1N3210 do not Inspect sample for solids and water
require a polarity check. contamination. Dismantle and clean
filter bowl as required. Replace filter
(d). Replace diodes, part number
element.
1N3210R with a new part number
1N3210 diode. (g). Inspect hose assemblies for evidence
of leakage, swelling or dampness,
(e). If the diode is unidentifiable, test kinks, cuts, twists, tears and fraying.
diode to determine polarity. Check hose nut threads for damage.
1). Check for low forward resistance Replace damaged parts.
with ohmmeter positive lead (h). Disconnect drain tubes from drain
attached to terminal end and valves. Check each drain valve for
negative lead attached to stud end. leakage. Replace damaged drain
Reverse leads and check for very valves.
high resistance.
(i). Inspect filter fuel line fittings for
(f). Replace diode with a new 1N3210 leakage. Repair or replace parts as
unit if polarity is reversed. required.
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282500 Revision 20
MAINTENANCE MANUAL
(j). Connect drain tubes to drain valves. (c). Start pump stops running.
Inspect drain tubes for security and
(5). Inspect fuel system for leakage.
correct routing without fluid traps or
kinks. 3. AntiIce Fuel Filter Installation
Operational Check: 369H90022503, 505
(k). Inspect fuel filter presstotest and 600N98110501
button for security.
(1). Apply external power to the helicopter.
2. AntiIce Fuel Filter Installation Set battery switch to EXT PWR.
Operational Check: 369H90022BSC (a). Reset PNL LT circuit breaker.
NOTE: The system may be operated with a ful- (b). Press PRESS TO TST WRN LT on
ly charged battery that can provide more the caution/warning light panel.
than the 23.8 Vdc required to actuate sys- Check entire caution/warning light
tem solenoids. If battery state is an un- array. Replace lamps as required.
known, use external power. (c). Push FUEL VALVE knob in to open
(1). Apply external power to the helicopter. fuel shutoff valve.
Set battery switch to EXT PWR. (2). Set START PUMP switch ON.
(a). Reset PNL LT and FUEL ANTI (a). START PUMP ON indicator light
ICE circuit breakers. comes on and start pump pressurizes
fuel system.
(b). Press PRESS TO TST WRN LT on
(3). Open the engine compartment doors.
the caution/warning light panel.
Check entire caution/warning light (4). Press the red presstotest button on
array. Replace lamps as required. top of airframe filter body. Result shall
be:
(c). Push FUEL VALVE knob in to open
fuel shutoff valve. (a). AIRFRAME FILTER caution light
comes on.
(d). Open the engine compartment doors. (5). Release the presstotest button.
(2). Press the red presstotest button on (a). AIRFRAME FILTER caution light
top of the filter body for five or more goes out.
seconds. Test results shall be as follows:
(6). Set START PUMP switch OFF.
(a). FUEL FILTER caution light comes (7). Inspect fuel system for leaks.
on.
4. Fuel System Vacuum Leak Check
(b). START PUMP ON indicator light
(1). Fuel is drawn out of the tank by the
comes on and start pump pressurizes
engine driven fuel pump when the start
fuel system.
pump is switched off. Water, ice, dirt,
(3). Release the presstotest button. fungus, trapped air or a few pinhole
leaks in the supply system between the
(a). FUEL FILTER and START PUMP fuel tank sump pickup and engine
ON lights remain on and start pump combustion chamber nozzles may cause
continues to operate. power surges, deceleration and, or
flameout. A vacuum leak inspection will
(4). Press FUEL FILTER caution light to determine whether or not air can be
reset system. Result shall be: drawn into the fuel system by the
engine driven fuel pump.
(a). FUEL FILTER caution light goes
out. (2). An automotive vacuum test pump and
hardware that will provide 8 Hg
(b). START PUMP ON indicator light vacuum or better is required to do the
goes out. vacuum leak check.
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Revision 20 282500
MAINTENANCE MANUAL
(3). Assemble vacuum pump, hoses, filter (b). Fuel system shall hold vacuum
port adapter, shutoff valve and vacuum between 8 and 7.5 Hg for two min-
gage as follows: utes.
(a). Insert a vacuum gage in the vacuum (c). If test is satisfactory, remove test
hose between the engine fuel filter apparatus. Inspect and replace filter
port adapter and vacuum shutoff plug Oring as required. Install filter
valve. Attach the vacuum pump to plug.
the vacuum hose above the shutoff
valve. (6). Vacuum loss exceeding 0.5 Hg in two
(b). Plug vacuum hose and pull 5 10 Hg minutes indicates a leak somewhere in
vacuum. Apparatus should hold the the system between the fuel shutoff
selected pressure indefinitely. Repair valve and engine.
leaky equipment before proceeding
with fuel system test. (a). Torque fuel line connections (Ref.
Table 601). Repeat vacuum test.
(c). Open engine access doors.
(b). If system continues to leak, discon-
(d). Remove left fuel cell floor access nect and install airtight caps or plugs
panel. in tubes, hoses and fitting ports in a
(e). In crew compartment; pull FUEL progressive sequence from fuel
shutoff valve knob out to stop. Verify shutoff valve toward engine. The fuel
that fuel shutoff valve lever on left shutoff and drain valve installations
fuel cell access cover is hard against should be especially suspect. Apply
its OFF stop. Rig control cable as vacuum at each stage until leak has
required. been isolated. Replace parts as
required.
(f). In engine compartment; remove the
upper drain plug from the fuel pump (c). Apply a torque stripe to all effected
filter bowl. fuel line fittings and nuts.
(4). Disconnect the fuel bleed return line at (d). If the airframe system vacuum held
Sta. 124.00 (if equipped) and cap off. at 7.5 Hg or better, system seal is
(5). Attach vacuum test apparatus to satisfactory and malfunction is
engine fuel filter upper drain port. probably due to an engine system
leak. Refer to the applicable Allison
(a). Apply 8 Hg vacuum. Close vacuum and Bendix manuals for additional
line shutoff valve. information.
Table 601. Fuel Supply System Torque Values
Torque Range
Item & Location InchPounds (Nm)
Tube endnuts; fuel shutoff valve; Sta. 124.00 Blkhd elbow 230 260 (25.99 29.38)
Blkhd elbow jamnut; Sta. 124.00 145 155 (16.38 17.51)
Threeport elbow jamnuts 145 155 (16.38 17.51)
Antiice filter drain fitting bolt 185 200 (20.90 22.60)
Antiice filter in/out reducers 550 600 (62.14 67.79)
Hose endnuts; firewall/filter 230 260 (25.99 29.38)
Hose endnuts; filter/engine 230 260 (25.99 29.38)
Drain valves (all) 95 105 (10.73 11.86)
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MAINTENANCE MANUAL
AIRFRAME FILTER CAUTION LIGHT

CAUTION LIGHT TEST
CAUTION LIGHT CAUTION LIGHT

RESET SWITCH TEST
FUEL SHUTOFF
PNL LT CIRCUIT
BATTERY BREAKER
SWITCH
PRESS
TO
TEST
START PUMP
SWITCH
DIMMER
POT
DIMMER
SWITCH
CIRCUIT
BREAKER
369H90022503, 505
PULL
TO
P CLOSE
U ON
S START
H
PUMP
FUEL SHUTOFF
START PUMP
SWITCH BATTERY
O
F
F
BATTERY
SWITCH
369H90022BSC
G2820041
Figure 601. AntiIce Fuel Filter Controls (Sheet 1 of 2)
Page 604
Revision 19 282500
MAINTENANCE MANUAL
AIR FRAME FILTER

(DS21)
CAUTION LIGHT
AIR FILTER CLOGGED TEST
(DS22)
FUEL SHUTOFF
BATTERY SWITCH
FUEL PUMP SWITCH

(CB118)
FUEL PUMP LIGHT

(XDS7)
600N98110501
G2820042
Figure 601. AntiIce Fuel Filter Controls (Sheet 2 of 2)

282500 Revision 19
MAINTENANCE MANUAL

NOTE: On the 600N helicopter, the airframe tal and drill three 0.219 inch (5.56 mm)
fuel filter is not certified as an antiice fuel diameter holes in pedestal.
fuel filter will be refered to as an antiice (3). Make cutout shown in instrument
fuel filter. pedestal fairing.
(4). Deburr holes and cutout edges. Remove
1. AntiIce Fuel Filter Initial Installation debris.
A. Preparations for Installation (5). Install rivnut and attach antiice fuel
filter panel to instrument pedestal with
Prevent fuel vapor ignition. screws, washers and spacers.
WARNING Turn OFF and disconnect all
electrical power. Attach helicopter to (6). Connect wires (Ref. Figure 903).
approved grounding points before
opening fuel system. (7). Install cover and screws.
(8). Install ANTIICE FUEL FILTER
(1). Disconnect external power and battery.
INSTALLATION placard decal on
(2). Remove aft compartment seats. heater duct three inches (7.62 cm)
above standby compass bracket. Roll
(3). Remove aft upper left bulkhead panel. placard edges to follow duct contour.
(4). Remove lower aft bulkhead panel. (9). Seal both ends of electrical conduit with
silicone adhesive/sealant (CM430).
(5). Remove pilot compartment left floor
C. AntiIce Fuel Filter Control Panel
access door.
Installation: 369H90022503, and 505
(6). Remove instrument panel hood and left
fairing. Consumable Materials
(7). Pull FUEL VALVE knob to close fuel Item Nomenclature
shut off valve.
B. AntiIce Fuel Filter Control Panel
Installation: 369H90022BSC (1). Pull fuel filter wire harness forward
through conduit and along an existing
Consumable Materials wire bundle to instrument pedestal.
(Ref. Section 910000) (2). Secure wire to engine compartment
Item Nomenclature airframe with clamps, screws, washers
CM430 Sealant, solvent resistant and nuts and to wire bundle with
tyraps (Ref. Figure 901).
(1). Pull filter wire harness forward (3). Install 20 gage bus wire and insulating
through conduit and along an existing sleeve on back side of caution light
wire bundle to instrument pedestal. DS31 (Ref. Figure 904).
Secure to engine compartment airframe
(4). Remove fourth plug from the right on
with clamps, screws, washers and nuts
caution/warning light panel.
and to wire bundle with tyraps (Ref.
Figure 901). (5). Wire and connect electrical system (Ref.
Figure 904).
(2). Use antiice fuel filter subpanel as a
template on left side of slimline pedes- (6). Install caution light in panel.
Page 901
282500 Revision 20
MAINTENANCE MANUAL
(7). Install ANTIICE FUEL FILTER E. Firewall Modifications and Bracket

INSTALLATION placard decal on Installation
heater duct three inches (7.62 cm)
above standby compass bracket. Roll (Ref. Figure 901 for 369H90022BSC, 503
placard edges to follow duct contour. and 505)
(Ref. Figure 902 for 600N96110501)
(8). Seal both ends of electrical conduit with
silicone adhesive/sealant (CM430).
D. AntiIce Fuel Filter Control Panel (Ref. Section 910000)
Installation: 600N98110501 Item Nomenclature
(Ref. Figure 601) CM318 Primer
(1). To install caution/warning light:

(1). Open engine access doors.
(a). Remove third plug from the right on (2). Drain fuel from supply lines into a
caution/warning light panel. suitable container.
(b). Install caution light in panel. (3). Remove fuel supply hose between
engine driven fuel pump and firewall
(c). Install 22 gage jumper wire on back
fitting elbow. Cap hose ends, firewall
side of caution lights between DS21C
elbow and fuel pump port.
and DS22C.
(4). Reposition firewall elbow 18 22
(d). Run O506D22 wire from DS212 to clockwise (Ref. view A).
P1214 and secure to existing wires.
Do not score, scratch or gouge
(2). To install fuel pump switch and light: CAUTION firewall surface when trimming
insulation blanket.
(a). Remove edgelighted switch panel.
(5). Lay out and remove insulation strips
(b). Remove tape from start pump switch from firewall to eliminate interference
and light holes in instrument panel. with filter support bracket installation.
(c). Install CB118 in panel. (6). Position doubler on Sta. 124.00 firewall.
Identify, mark and drillout existing
(d). Run 22 gage jumper wire from rivets used in doubler installation. Do
CB1151 to CB1181. not enlarge rivet holes.
(e). Run Q1169A22 wire from CB1182 to (7). Locate doubler on firewall forward
TB50322. surface. Drill doubler through existing
rivet holes.
(f). Install light (XDS7) from back side of
panel. (8). Deburr holes and remove debris.
(g). Run E1181A22 wire from P1346 to (9). Cleco doubler to firewall.
XDS7.
(10). Apply primer (CM318) to rivet holes
(h). Run E1181B22N wire from XDS7 to and rivets.
E31E.
(11). Install rivets while primer is wet.
(i). Reinstall edgelighted switch panel. (12). Use filter support bracket as a tem-
(3). Install ANTIICE FUEL FILTER plate. Mark and drill filter bracket rivet
INSTALLATION placard decal on holes.
heater duct three inches (7.62 cm) (13). Deburr holes and remove debris.
above standby compass bracket. Roll
placard edges to follow duct contour. (14). Cleco bracket in position.
Page 902
Revision 20 282500
MAINTENANCE MANUAL
(15). Apply primer to rivet holes and rivets. (4). Apply a thin coat of antiseize com-
pound (CM113) to fittingbolt threads.
(16). Rivet bracket in place while primer is Stack fitting and gaskets on bottom of
wet. filter. Install and torque bolt 185 200
(17). Install electrical bonding jumper
between bracket and airframe. (5). Lubricate drain valve Oring packing
with clean jet fuel and install on drain
(18). Position double aft of Sta. 124.00 valve. Apply a thin coat of antiseize
between LBL 4.250 and LBL 8.450. compound to drain valve threads.
Drill rivet holes and cleco in place.
(6). Install drain valve with Oring packing
(19). Drill hole for drain hose. on fuel filter drain fitting. Torque drain
valve 95 105 inchpounds (10.73
(20). Remove doubler , deburr and remove 11.86 Nm).
debris.
(7). Install and clamp drain tube to drain
(21). Apply primer (CM318) to rivet and valve with lockwire.
drain holes.
NOTE: Provide enough slack in drain tubes to
(22). Install doubler while rivets are still allow unrestrained drain valve operation.
wet.
(8). On 600N96110501 installation, install
F. Fuel Filter Installation mount to firewall using adhesive
(CM438).
WARNING cause a power reduction or (9). Clamp tube to bulkhead frame or
flameout. Do a fuel system vacuum leak mount at LBL 8.45 with TY25M
check and system air bleed after open- TYRAP.
ing fuel system to atmosphere and (10). Lubricate the two reducer Orings with
prior to releasing helicopter for flight. clean jet fuel. Install Orings on large
Ensure start pump is operating before ends of reducers. Apply a thin coat of
taking fuel samples from system drain antiseize compound to reducer
valves. threads.
(Ref. Figure 901 for 369H90022BSC, 503 (11). Install reducers with Orings in filter
and 505) inlet and outlet ports. Torque reducers
(Ref. Figure 902 for 600N96110501) 67.79 Nm).
Do not allow hose to twist when
Consumable Materials CAUTION torquing hose nuts. Use a back-
(Ref. Section 910000) up wrench to stabilize hose.
Item Nomenclature
CM113 Antiseize compound low temperature (12). Connect hose between filter outlet port
and engine fuel pump filter inlet port.
Torque hose nuts 230 260 inch
pounds (25.99 29.38 Nm).
(1). Remove engine gearcase cooling duct (13). Install hose between filter inlet port
clip and attaching hardware. and firewall fitting elbow. Torque hose
(2). Drill a 0.250 inch (6.35 mm) diameter nuts 230 260 inchpounds (25.99
hole and relocate clip. 29.38 Nm).
(14). Secure hoses with clamps, screws,
(3). Install filter assembly on bracket with washers and nuts.
bolts, washers and spacers. Torque
bolts 50 70 inchpounds (5.65 7.91 (15). Install wire connector plug on filter
Nm). Install lockwire. receptacle.
Page 903
282500 Revision 28
MAINTENANCE MANUAL
BOLT, WASHER,
LOCKWIRE
RIVET HOSE
(7 PLCS)
(NOTE 1)
BRACKET
(NOTE 2)
HOSE
(TANK TO FILTER)
LOOKING DOWN
CLAMP, SCREW, 0.75 INCH
WASHER, NUT (17.05 MM)
(NOTE 10) CLAMP, SCREW
WASHER, (2 REQD) 0.260 INCH (6060 MM)
RIVET NUT DIA HOLE
RIVET RIVET
(NOTE 9) (NOTE 8)
CLAMP (NOTE 8)
(2 PLCS) ENGINE FUEL
DUCT (REF) PUMP (REF)
WL 22.85
WIRE HARNESS
RIVET
(NOTE 8)
CLIP (NOTE 3) RIVET
RIVET (NOTE 1)
(NOTES 8, 9)
INSULATION
(REF) FILTER ASSY
RIVET ELBOW
(NOTE 8) (NOTE 4)
WL 13.10
LANDING GEAR DAMPER
(REF)
FITTING, BOLT
TORQUE TO 185200 INLBS
(20.9022.60 NM) A A
GASKET (2 REQD) (NOTE 7) 18
20
TUBE TY25N TYRAP
(NOTE 5)
CONDUIT
(REF)
WL 5.14
STA 124.0 CONDUIT (REF)
CLAMP, SCREW, (NOTE 6)
WASHER, NUT LBL 13.23
(NOTE 10) WIRE HARNESS ASSY
0.000.12 INCH
LBL 8.45 (0.003.05 MM)
(NOTE 15)
SCREW, CLAMP, LOOKING FORWARD
WASHER, NUT
(NOTE 10)
STA 137.50
VIEW AA
EFFECTIVITY: 369D/E 500N G2820031D
Figure 901. AntiIce Fuel Filter Modifications and Installation (369D/E 500N) (Sheet 1 of 2)
Page 904
Revision 19 282500
MAINTENANCE MANUAL
0.25 INCH
(6.35 MM)
STIFFENER 1.00 INCH
(2.54 CM)
PANEL 1.00 INCH
(2.54 CM) 1.75 INCH
(4.445 CM)
NOTE 13
INSULATION
PANEL
REDUCER (2 REQD) 5.00 INCH

STA 124.0 PACKING (2 REQD) (12.70 CM)
(NOTE 12)
BRACKET
DOUBLER
(NOTE 14)
HOSE ASSY
PANEL STIFFENER PANEL STIFFENER

SPACER
(3 REQD)
HOSE ASSY
DUCT
PLACARD
(NOTE 11)
WL 13.10
3.00 INCH
(7.62 CM)
VALVE PACKING
(NOTE 12)
TUBE
COMPASS BRACKET
(REF)
7.25 INCH 0.12 R

(18.415 CM) (TYP)
5.50 INCH
(13.97 CM)
DOUBLER
EFFECTIVITY: 369D/E 500N G2820032D
Figure 901. AntiIce Fuel Filter Modifications and Installation (369D/E 500N) (Sheet 2 of 2)
Page 905
282500 Revision 19
MAINTENANCE MANUAL
NOTE:
(1) Pick up existing rivet locations, seven places. Install MS296154M rivets or NAS1738 M4 alternates. Install
rivets in wet MILP23377 Type 1, Class 1, epoxy primer or, MILP8585 primer.
(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA
publication EAAC43.131A and 2A.
(3) Reposition clip 0.75 inch (19.05 mm) inboard.
(4) Shim elbow to 1822 degrees clockwise.
(5) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.
(6) Seal both ends of conduit with RTV 732 sealant/adhesive after wire harness installation.
(7) Apply low temperature antiseize compound, MILT5544B Thread Lube or equivalent to assembly
threads prior to installation. Torque bolt 185 200 inchpounds (20.90 22.60 Nm).
(8) Install MS206153M rivets in wet MILP23377, Type 1, Class 1, epoxy primer or, MILP8585 primer.
(9) Install MS206154M or alternate NAS1738M4 rivets in wet MILP23377, Type 1, Class, 1 epoxy primer
or, MILP8585 primer.
(10) Clamp wire harness in place as shown using existing tool holes.
(11) Roll placard edges to follow heater duct contour.
(12) Apply MILT5544B low temperature antiseize compound to threads prior to assembly.
(13) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not
scratch firewall surface.
(14) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.
(15) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.
Page 906
Revision 19 282500
MAINTENANCE MANUAL
ENGINE INSTALLATION
CLAMP, SCREW
WASHER (2 REQD) LBL
NUT 8.450 RIVET
(NOTE 8) (NOTE 6)
CONNECTOR
WL
22.850
REDUCER
ORING
(NOTE 9)
HOSE
FILTER
MOUNT
(NOTE 4)
BOLT NUT
WASHER ORING HOSE 0.000.12 INCH
RIVET (7 PL) LBL (NOTE 3) (0.003.05 CM)
BUSHING (NOTE 12)
(NOTE 1) ORING 8.450
BULKHEAD ELBOW
FS
124.000 LOOKING FORWARD
CLAMPS,
HOSE SCREW
(TANKTOFILTER) WASHERS,
NUT
FS
137.500
BRACKET
(NOTE 2)
LOOKING DOWN
Figure 902. AntiIce Fuel Filter Modifications and Installation (600N) (Sheet 1 of 2)
Page 907
282500 Revision 19
MAINTENANCE MANUAL
1.00 INCH
STIFFENER (2.54 CM)
1.75 INCH
(4.45 CM)
STIFFENER
PANEL NOTE 10
STIFFENER 0.25 INCH

(6.35 MM) 1.00 INCH
(2.54 CM)
INSULATION
5.00 INCH
(12.70 CM)
PANEL
SPACER
(3 REQD)
PANEL PANEL
LOOKING FORWARD
WL
13.100
FITTING, BOLT
TORQUE TO 185 200 INCHPOUNDS
(20.90 22.60 NM)
GASKET (2 REQD) (NOTE 5)
DRAIN VALVE ORING
(NOTE 9)
DOUBLER
LBL (NOTE 11) RIVET
8.450 (NOTE 1) FS
137.000
RIVET
(NOTE 7) LOOKING INBOARD
FS LEFT SIDE
WL 124.000
22.850
RIVET RIVET
(NOTE 6) (NOTE 1)
LBL LBL
8.450 4.250
RIVET
(NOTE 6, 7) RIVET FS
RIVET (NOTE 1) 124.000
(NOTE 6)
LOOKING AFT
DOUBLER
RIVET GROMMET
LOOKING DOWN
Figure 902. AntiIce Fuel Filter Modifications and Installation (600N) (Sheet 2 of 2)
Page 908
Revision 19 282500
MAINTENANCE MANUAL
NOTE:
(1) Pick up existing rivet locations, seven places. Install MS296154M rivets or NAS1738 M4 alternates. Install
rivets in wet MILP23377 Type 1, Class 1, epoxy primer or, MILP8585 primer.
(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA
publication EAAC43.131A and 2A.
(3) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.
(4) Install with adhesive CM438.
(5) Apply low temperature antiseize compound, MILT5544B Thread Lube or equivalent to assembly
threads prior to installation. Torque bolt 185 200 inchpounds (20.90 22.60 Nm).
(6) Install MS206153M rivets in wet MILP23377, Type 1, Class 1, epoxy primer or, MILP8585 primer.
(7) Install MS206154M or alternate NAS1738M4 rivets in wet MILP23377, Type 1, Class, 1 epoxy primer
or, MILP8585 primer.
(8) Clamp wire harness in place as shown using existing tool holes.
(9) Apply MILT5544B low temperature antiseize compound to threads prior to assembly.
(10) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not
scratch firewall surface.
(11) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.
(12) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.
Page 909
282500 Revision 19
MAINTENANCE MANUAL
369H901613 HARNESS ALL

PANEL NUMBERED WIRE 20 GA
369H4742 SWITCH ASSEMBLY MS1782119 STRAP A/R
Q510D20N
2 AMBER 2
7
E23 Q501CC20
C D CR25 6
B A CR23
2 2 CR26
Q503B20
NC
C 1
S3 NO
NC 5
E509B20
C Q501A20
S1 NO
NC Q506A20
C
S2 NO
CR27 X1+
NOTE 2 VARISTOR
K254 Q507A20
3
X2
LOAD + TB22
PRESSTOTEST
KD1
CB135
P506BA20 7.5
ANTIICE BRIGHT
FUEL FILTER
R254
DIM R
ANTIICE CAUTION LIGHT TB101
DIMMER SWITCH 100 OHM 5 1/4W
3
G2820011
Figure 903. AntiIce Fuel Filter Wiring Diagram (369D S/N 0001 1204) (Sheet 1 of 2)
Page 910
Revision 19 282500
MAINTENANCE MANUAL
TB6
Q510D20N 3
START PUMP
"ON" LT SP23
SP24
2 1
Q501CC20 A B E561B22 E560B22 B A E560A22N 6
ZDS7
NOTE 1
XDS9
START PUMP NC
1 2
28 VDC NOTE 1 S2 GRD
CB118 NO S21
7.5A (REF) WARNING LGT.
LAMP TEST
Q503B20 NC
S1 +28 VDC
NO
E509B20
Q501A20 TO START PUMP
369H8021 FILTER
P252 SPLICE PERMISSIBLE
Q506A20 A
NO
C
NC
Q507A20 PRESSURE SWITCH

AIFRAME FUEL NOTES:
FILTER 1. CAP AND STOW ENDS OF EXISTING WIRES
Q501C20 AT CB1182 AND EXISTING WIRE
E561A22 AT SP24A.
2. RT170277 TIME DELAY RELAY (REF)
CA3108ER12S3S
CONNECTOR
G2820012
Wire Data List

Wire No. From Termination To Termination
Q507A20 CB1352 MS25036149 P252B CRIMP
Q506A20 TB223 MS25036101 P252A CRIMP
Q501A20 (REF) TB221 MS25036101 TO START PUMP
E509B20 TB225 MS25036101 S21S1 (NO) SOLDER
Q503B20 TB226 MS25036101 CB1182 MS25036149
Q501CC20 TB227 MS25036101 SP24A 32445 (AMP)
Q510D20N E23 MS25036101 TB63 MS25036101
P506BA20 CB1351 MS25036149 TB1013 MS25036101
Figure 903. AntiIce Fuel Filter Wiring Diagram (369D S/N 0001 1204) (Sheet 1 of 2)
Page 911
282500 Revision 19
MAINTENANCE MANUAL
E31 A B C P514A20
WARNING LIGHT
D E F TEST SWITCH
G H J
ZDS21S2 (REF)
NC
K L M
E511B20 C
NO
TB50312 A B C
CA3108ER12S3S
CONNECTOR
D E F
P252
G H J P9J NO
K K A
M531C20 K L M C
E511BB20 B
L
NC
F A Q506B20 E13 GRND 369H8021 PRESSURE SWITCH
AIRFRAME FUEL FILTER
M
G B
N
H C Q506C20 3 C 2
P
TB5051/2 J
D
4 1
R 20 GA BUS WIRE
K
E AND SLEEVING
D531 AIRFRAME FILTER

A B C CAUTION INDICATOR
D E F
(REAR VIEW)
TB5034 Q514B20
G H J
P12
DIMMER
K L M
B DC GROUND TEST
CB104
1 2 E508A20 V +28 VDC PWR
A B C
L532A20
5A E518A20 T PRESSURE TEMP WARN
WARNING D E F SIGNAL
PNL LTS G H J E559A20 D WARNING LT. DIMMER
TB5036 K L M
Q514A20
DASHED LINES ARE EXISTING WIRES
G282002
Wire Data List

Wire No. Wire Type From Termination To Termination
Q506A230 M81381/1120N J9K MS3192A20A P252A CRIMP
Q510F20N M81381/1120N E13 M7928/124 P252B CRIMP
Q506C20 M81381/1120N TB5051/2B M39029/222020 TB5034E MS39029/222020
Q514B20 M81381/1120N TB5034D M39029/222020 DS312 SOLDER
Q514A20 M81381/1120W TB5036L M39029/222020 DS31C SOLDER
Figure 904. AntiIce Fuel Filter Wiring Diagram (369D S/N 1205 & Subs and 369E S/N 001 383)
Page 912
Revision 19 282500
MAINTENANCE MANUAL
P12J DIMMER
TB503
1 TB503
CB10 F 2
4 A
B NO B TB503
K 2
C G
C NC
E3
3 NO W1237A2 F
B 2
W1040C2
2 C E
NC
XDS21 WARNING
PRESSTOTEST
DS31 AIRFRAME
FILTER
Q506D2
2
Q506D2
2 TB503
2
J K LL M
TB5061/2
L
W1237A22 F TB5038
A
M
G LR
B Q1232C22 N P S
H N
C
P
J
D
K R
E
Q506C22
P1201J J1301P
P252
Q506A22 NO
69 Q506B22 f A
Q510F22N B
NC
E13
G282005
Figure 905. AntiIce Fuel Filter Wiring Diagram (369E S/N 384 & Subs and 500N S/N 001 & Subs)
Page 913
282500 Revision 19
MAINTENANCE MANUAL
CB115
(ANTICOLLISION LTS.)
P2002A12 1 3A 2
22AWG
JMPR
CB118
(START PUMP)
1 7.5A 2 Q1169A22
BUS 3 P2003A10
P 12 J J 13 P
CR39 CR47
39 39
22AWG
JMPR
46 46
DS22 (AIR FILTER CLOGGED)

P1233C22 9
AMBER LAMP
W1040F22 53
DS21 (AIR FRAME FILTER)

Q506D22 14 14
AMBER LAMP
CR14
22AWG JMPR
NC
DC GROUND TEST 49 C
NO
49
50 NC 14V
C
+28VDC TEST 51 NO
NO NC NO NC XDS24
WARN LTS.
C S2 C S1 PTT
52 50
51
SWITCHING 52
REGULATOR
DIMMER CONTROL UNIT

G2820061
Figure 906. AntiIce Fuel Filter Wiring Diagram (600N S/N 003 & Subs) (Sheet 1 of 2)
Page 914
Revision 19 282500
MAINTENANCE MANUAL
TB5032
4
A B C D
E F G H P 1201 J
FUEL PUMP
J K L M
P/J 250 B250
Q1169A22 Q1170A22 27 Q1170B22 A
E37
N P R S
H G E F Q1170A22N B
E31
T W Y Z
A B C D
J 13 P
E F G H
39 Q1235C22 XDS7 J K L M
(START PUMP ON LTS.)
46 E1181A22 E1181B22N N P R S
T W Y Z
P252
14 Q506B22 69 Q506A22 A AIR FRAME
R110 FILTER
PANEL LTS. DIMMER POT. E13 Q510F22N B
6 7 (PUSH TO DIM CAU/WARN LTS)
49 4 5
CB104
3 (PNL. LIGHTS)
2
B 2 3A 1
1
W
G
50 +28VDC F
51 DC GROUND
P
52 DIMMER POT. ARM
K G2820062
Wire Data List

Wire No. From Termination To Termination
JUMPER22 CB1151 HDS4123126 CB1181 HDS4123126
O1169A22 CB1182 HDS4123126 TB50322 HDS4123904
(1) O1170A22 TB5032R HDS4123904 P120127 HDS4123916
O1236C22 TB5032N HDS4123904 P1339 HDS4123926
(2) JUMPER P1239 HDS4123926 P1246 HDS4123926
(3) E1181A22 P1346 HDS4123926 XDS7 HDS4123999
E1181B22N XDS7 HDS4123999 E31E HDS4123904
(2) JUMPER22 DS22C HDS4123999 DS21C HDS4123999
(1) O506D22 DS212 HDS4123999 P1214 HDS4123926
(1) O506A22 J120169 HDS4123915 P252A CRIMP
(3) O510F22N P252B CRIMP (4) E13 HDS4123135
NOTES:
(1) Wire capped and stowed (part of existing wire harness).
(2) Do not exceed three inches (7.62 cm).
(3) Wire connected to ground.
(4) E13 Ground stud mounted on left oleo support.
Figure 906. AntiIce Fuel Filter Wiring Diagram (600N S/N 003 & Subs) (Sheet 2 of 2)
Page 915
282500 Revision 19
MAINTENANCE MANUAL
(16). Measure electrical resistance between Prevent fuel system contamina-

filter bowl and firewall. Resistance CAUTION tion. Install caps on the ends of
shall not be more than 0.003 ohms. hoses, tubes and fittings as the parts are re-
G. PostInstallation Inspection vent loss or damage.
(1). Ensure that all installation debris has (1). Defuel helicopter (Ref. Sec. 120000).
been removed. Drain remaining fuel from tank sump
drain valve into a suitable container.
(2). Check all electrical connections for
correct routing and security. (2). Disconnect electrical power.
A. Fuel Cell Cover Removal
(3). Ensure that all hardware, tubes, and
hoses are properly secured. (1). To remove left aft fuel cell access cover:
(a). Remove left aft fuel cell access panel
(4). Ensure that no fuel can be trapped by from passenger/cargo compartment
the drain system. floor.
H. Furnishings, Panels and Equipment (b). Unclamp and disconnect control
Installation cable from fuel shutoff valve.
(1). Install instrument panel hood and (c). Disconnect engine feed fuel supply
instrument panel left side fairing. hose assembly between fuel shutoff
valve and Sta. 124.00 bulkhead. Use
(2). Install pilots compartment left floor backup wrench on fuel shutoff valve
access panel. so it will not rotate.
(3). Install upper left aft bulkhead panel (d). Disconnect motive flow fuel hose
and lower aft bulkhead panel. assembly between Sta 124.00 bulk-
head and fuel cell access cover.
(4). Install aft compartment seats. (e). Disconnect fuel quantity probe wire
(5). Close engine access doors. harness connector from fuel cell cover
receptacle.
(6). Connect battery. (f). Unfasten and remove Sta. 91.00 and
102.00 left aft fuel cell cover support
2. AntiIce Fuel Pump Initial Installation
brackets.
(600N98110501 Installation)
(g). Remove cover bolts and washers.
(Ref. Figure 907) Prop cover open with suitably padded
blocks.
Consumable Materials (h). Using a backup wrench on valve,
(Ref. Section 910000) separate engine feed fuel cell supply
Item Nomenclature hose from fuel shutoff valve and fuel
CM114 Petrolatum inlet from fuel cell access cover.
CM124 Kerosene (i). Disconnect submerged motive flow
CM702 Lockwire CRES fuel hose assembly between fuel
check valve and ejector pump from
fuel cell access cover.
WARNING and fire. Use only nonspark- (j). Disconnect fuel cell scavenge hose
ing tools and explosion proof work assembly from bottom of fuel cell
lights. Attach helicopter to an ap- access cover bracket assembly to
proved electrical ground. Switch OFF ejector pump.
all electrical power. Disconnect exter- (k). Cut safety wire from fuel probe
nal power and battery before opening electrical connector base nut and
fuel system. Ensure work area is ade- remove connector from fuel cell
quately ventilated. access cover.
Page 916
Revision 19 282500
MAINTENANCE MANUAL
FUEL PROBE FS
93.15
HOSE
BL
0.00 P250 WIRE HARNESS
FUEL CELL WIRE HARNESS
COVER
WL 13.10
BOLT
WASHER
LBL 13.00
PUMP
WL 0.00 UNION
ORING
SPACER
BRACKET
VIEW LOOKING AFT
FS
95.628
VIEW LOOKING DOWN G282007
Figure 907. Fuel Pump Initial Installation (600N)
(l). Remove fuel cell scavenge hose (5). Attach fuel supply hose to pump
bracket assembly, bulkhead union pressure port union. Torque hose nut to
and fuel shutoff valve from fuel cell 230 260 inchpounds (25.99 29.38
cover. Nm).
(2). Remove unused bulkhead union from C. Fuel Cell Cover Installation
cover.
B. Pump Installation (1). Wipe fuel cell and cover sealing sur-
faces clean with kerosene (CM124) on a
(1). Disconnect fuel feed hose from fuel inlet clean lint free cloth.
plate and remove plate.
(2). Inspect fuel cell cover seals for debond-
(2). Clean pump and sump plate mount ing, nicks or cuts and any other damage
contact surfaces to establish an electri- having a leak producing potential.
cal bond. Replace covers or left aft cover as
required.
Do not mark torque alignment
CAUTION stripes on fuel cell internal
hardware. (3). Install left aft fuel cell access cover as
follows:
(3). Install pump on sump plate with bolts,
washers and spacers. Torque bolts to 36 (a). Apply a coating of petrolatum
46 inchpounds (4.07 5.20 Nm). (CM114) to a new fuel shutoff valve/c-
over sealwasher. Install valve on cell
(4). Apply a thin coat of petrolatum cover with sealwasher next to valve
(CM114) to a new Oring and pump body and valve properly aligned to
pressure port union threads. Install make connection with valve control
Oring on union. Install union in pump cable. Torque valve jamnut to 240
pressure port and torque to 280 305 280 inchpounds (27.12 31.64
inchpounds (31.64 34.46 Nm). Nm).
Page 917
282500 Revision 19
MAINTENANCE MANUAL
(b). Apply a coating of petrolatum to (9). Install three support brackets on Sta.
sealwasher. Install check valve and 91.00 and 102.00 floor crossmembers
sealwasher to inside cover and a with washers and screws. Torque
plain washer outside. Torque jamnut screws to 20 25 inchpounds (2.26
to 85 105 inchpounds (9.6 2.82 Nm).
11.86 Nm).
(10). Install cover bolts and washers. In a
(c). Install bulkhead elbow to support cross pattern, progressively torque
bracket. with washer and nut. Torque cover bolts to 70 90 inchpounds
jamnut to 240 280 inchpounds (7.91 10.17 Nm).
(27.12 31.64 Nm).
(11). Connect engine feed fuel supply hose to
(d). Install support bracket to cover with fuel shutoff valve. Torque hose nut to
bolts, washer, and sealwashers. 230 260 inchpounds (25.99 29.38
Apply a coating of petrolatum to Nm).
sealwasher. Torque bolts to 36 46
inchpounds (4.06 5.19 Nm). (12). Connect fuel motive flow hose to access
cover/check valve. Torque hose nut (50
(4). Place left aft fuel cell access cover into 65 inchpounds (5.65 7.34 Nm).
position on fuel cell.
(13). Connect fuel quantity probe and pump
NOTE: Install new seal washer, AS3578024, connectors to wire harness receptacles.
on wire harness connector.
(14). Slip control cable through hole in fuel
(5). Connect fuel quantity probe and pump shutoff valve lever swivel.
wire harness connectors to cell cover.
Torque connector jamnuts and safety-
(15). Rig cable control system. (Ref. Sec.
wire to bulkhead union with lockwire
280060, Fuel Shutoff Valve Control
(CM702).
Cable Installation).
(6). Install fuel cell inlet hose assembly to
access cover fuel shutoff valve. Torque (16). Apply a torque alignment stripe to fuel
hose assembly 230 260 inchpounds line tube, hose and fitting fasteners.
(25.99 29.38 Nm).
(17). Install access panels on passenger
(7). Install submerged motive flow hose cargo compartment floor.
assembly to access cover check valve.
Torque hose assembly 50 65 inch 3. AntiIce Fuel Filter Installation Weight
pounds (5.65 7.34 Nm). and Balance
(8). Install scavenge fuel cell hose assembly (1). After installation of the antiice fuel
to access cover bulkhead elbow. Torque filter, incorporate changes to helicopter
hose assembly 230 260 inchpounds weight and balance record (Ref. Sec.
(25.99 29.38 Nm). Section 081000).

Configuration Weight Arm Moment
Pounds (kg) inches (cm) in.lb (kg cm)
369H90022BSC +6.6 (+2.996) 107.8 (273.81) +711.48 (+819.710)

369H90022503 +5.3 (+2.406) 122.7 (311.66) +650.31 (+749.235)
369H90022505 +5.3 (+2.406) 122.7 (311.66) +650.31 (+749.235)
600N98110501 +7.3 (+3.311) 112.7 (286.26) +822.7 (+947.807)
Page 918
Revision 19 282500
MAINTENANCE MANUAL
Chapter
32
Landing Gear
MAINTENANCE MANUAL
TABLE OF CONTENTS
321000 Landing Gear System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Entry Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Landing Gear Damper Nitrogen Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Landing Gear Damper Nitrogen Servicing On Helicopter . . . . . . . 302
Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended
Landing Gear Dampers on Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . 303
Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard
Landing Gear Dampers on Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . 306
1. Landing Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Landing Gear and Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Landing Gear Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Landing Gear Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Landing Gear Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Landing Gear Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Landing Gear Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Landing Gear Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Landing Gear Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Landing Gear Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
5. Cabin Entry Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Cabin Entry Step Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Cabin Entry Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Landing Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Landing Gear Skid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
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MAINTENANCE MANUAL

Figure 601. Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Landing Gear Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5. Cabin Entry Step Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6. Landing Gear Fairing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 601. Minimum Damper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 602. Landing Gear Damper Bench Test Requirements . . . . . . . . . . . . . . . . 605
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Landing Gear System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Skid Adapter Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Table 801. Maximum Damage Limits Landing Gear Components . . . . . . . . . . 802
Figure 801. Landing Gear Repairs (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
4. Ground Handling Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5. Safety Walk Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
6. Landing Gear Fairing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
7. Landing Gear Fairing Fillet Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8. Landing Gear Strut Drag Brace Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Landing Gear Strut with Bushing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. Landing Gear Strut with No Bushing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 802. Landing Gear Fairing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
1. Extended Landing Gear Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Standard Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Standard Landing Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Extended Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Extended Landing Gear Assembly (Early Configuration) . . . . . . . . . 902
Figure 902. Extended Landing Gear Assembly (Current Configuration) . . . . . . 904
D. Early Configuration Extended Landing Gear Assembly Buildup . . . . . . . . . . . . . 906
E. Current Configuration Extended Landing Gear Skid Tube Assembly
Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
F. Extended Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
G. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. Extended Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
321060 Landing Gear System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page ii
MAINTENANCE MANUAL

A. Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Entry Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Landing Gear Damper Nitrogen Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Landing Gear Damper Nitrogen Servicing On Helicopter . . . . . . . 302
Table 301. Nitrogen Recharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1. Landing Gear Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Landing Gear Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Landing Gear Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Landing Gear Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Landing Gear Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Landing Gear Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Landing Gear and Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Landing Gear Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Landing Gear Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Landing Gear Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Landing Gear Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Landing Gear Rubber Washer Locations . . . . . . . . . . . . . . . . . . . . . . . 407
1. Landing Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Landing Gear Skid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Landing Gear Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5. Forward Cabin Entry Step Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6. Landing Gear Fairing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Minimum Damper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Landing Gear System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
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MAINTENANCE MANUAL

3. Ground Handling Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Safety Walk Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
5. Landing Gear Fairing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Table 801. Maximum Damage Limits Landing Gear Components . . . . . . . . . . 802
324000 Ground Handling Wheels (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Ground Handling Wheel Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Standard Ground Handling Wheel Installation and Use . . . . . . . . . . . . . . . . . . . . . . . 201
3. Special Ground Handling Wheel Installation and Use . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Ground Handling Wheel Assembly (Standard) . . . . . . . . . . . . . . . . . . 202
4. Standard Ground Handling Wheel Disassembly (Early Configuration) . . . . . . . . . . 202
5. Standard Ground Handling Wheel Reassembly (Early Configuration) . . . . . . . . . 202
Figure 202. Ground Handling Wheel Assembly/Disassembly . . . . . . . . . . . . . . . . 203
6. Standard Ground Handling Wheel Disassembly (Current Configuration) . . . . . . . 204
7. Standard Ground Handling Wheel Reassembly (Current Configuration) . . . . . . . 204
8. Standard Ground Handling Wheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9. Special Ground Handling Wheel Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10. Special Ground Handling Wheel Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
11. Special Ground Handling Wheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Special Ground Handling Wheel Assembly (Float Type) . . . . . . . . . . 205
Figure 204. Special Ground Handling Wheel Assembly/Disassembly . . . . . . . . . 206
324060 Ground Handling Wheels (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Ground Handling Wheel Assembly Description and Operation . . . . . . . . . . . . . . . 201
2. Ground Handling Wheel Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Ground Handling Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
328100 Utility Float System (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Utility Float Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Utility Float Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Utility Float Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Skid Tube and Extension Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Utility Float Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Utility Float Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

Table 201. Troubleshooting Utility Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Utility Float Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Utility Float Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Utility Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Skid Tube Extension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Skid Tube Extension Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Skid Tube Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Utility Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1. Utility Float Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Disassembly of Extended Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Extended Landing Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 902
C. Landing Gear Strut Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
D. Landing Gear Skid Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Figure 902. Extended Landing Gear Modification . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 903. Skid Tube Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
E. Utility Float to Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
F. Utility Floats/Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 904. Utility Float Buildup (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
328200 Emergency Float System
(369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency Float System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Emergency Float Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Certification and Shelf/Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Emergency Float Inspection (Stowed Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Emergency Float Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Troubleshooting Emergency Flotation Equipment . . . . . . . . . . . . . . . . 203
5. Emergency Float Compartment Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Emergency Float Inspection (After Inflation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7. Emergency Float Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8. Float Compartments Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9. Emergency Float Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10. SolenoidtoSquib Rework Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1. Emergency Float Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Page v
MAINTENANCE MANUAL

A. Emergency Float Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Emergency Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Emergency Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Emergency Float Pressure Vessel Servicing and Replacement . . . . . . . . . . . . . . . . . 403
Figure 402. Solenoid Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3. Squib and Squib Actuated Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403. Squib Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4. Emergency Float Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 404. Emergency Float Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Emergency Float System Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Initial Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Existing Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Landing Gear Skid Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Emergency Float System Electrical Equipment Installation . . . . . . . . . . . . . . . . . 901
Figure 901. Emergency Float Kit Electrical Installation . . . . . . . . . . . . . . . . . . . 902
F. Emergency Float System Electrical Wiring Installation . . . . . . . . . . . . . . . . . . . . . 903
Figure 902. Emergency Float Inflation System Wiring Diagram
(369D290121501 and 505) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
(369D290121515, 517 and 519) (Sheet 1 of 2) . . . . . . . . . . . . . . . . 905
(369D290121521, 523, 525 and 527) (Sheet 1 of 2) . . . . . . . . . . . 907
Figure 905. Emergency Float Installation with Generic Wire Harness . . . . . . . . 909
G. Emergency Float Electrical System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
H. Emergency Float System Strut Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . 910
Figure 906. Emergency Float System Strut Fairing Installation . . . . . . . . . . . . . 911
I. Emergency Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Page vi
MAINTENANCE MANUAL
Section
321000
Landing Gear
System
(369D/E/FF 500N)
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

1. Landing Gear compartment seat structure. Aft damper
assemblies are attached to oleo support fittings
The landing gear consists of two strut in the engine compartment.
mounted, shockdampened skids aligned
longitudinally along the helicopter fuselage. The damper assemblies are approximately
Both right and left skids pivot as the damper 12.21 inches (31.01 cm) long when extended
assemblies extend and retract. Replaceable and 8.96 inches (22.76 cm) long when com-
abrasion strips are installed on each skid to pressed. The dampers are poppettype and
retard wear on hard surfaces. consist of a barrel, upper and lower mounting
cap, main poppet, rebound poppet and a
A. Skid piston. Damper exterior surfaces are painted
white for surface protection and as an aid to
Landing gear skids provide helicopter rest
identification.
mounts. Skid tubes are constructed from
seamless, extruded aluminum alloy tubing. A damper must be replaced if damaged, or if
Abrasion strips attached to undersides of skid loss of pneumatic pressure (nitrogen gas) or
tubes retard wear and damage. Ground hydraulic oil occurs.
handling fittings riveted to skid tubes are the
ground handling attach points. Forward end of D. Entry Step
skid contains provisions for night lighting
Entry steps mounted on the landing gear
equipment. An adapter sleeve at the aft end of
struts allow for easy access into cabin. The
skid tube provides a nonrigid mount for the aft
landing gear step is covered with nonskid
foot bearing and skid extension.
tape and attached to the landing gear strut
B. Strut with lockbolts.
The landing gear struts attach to the fuselage E. Fairing

center beam. Landing gear braces between the Fiberglass/aluminum fairings on each strut
landing gear strut and fuselage center beam reduce aerodynamic drag during flight. The
prevent shearing of the strut and keep the fairings extend from the fuselage to the skids
strut in alignment with the landing gear. At to form streamlined enclosures for the landing
the lower ends of the struts, footshaped gear struts. Each fairing assembly is con-
components attach the landing gear skids to structed of three main parts: a fillet, an upper,
the struts. Feet for the aft strut are bearing and lower twopiece fairing. The fillet is
mounted to provide a nonrigid and pivotal springloaded to remain in firm contact with a
mount. fiberglass rubbing plate that is bonded and
C. Damper riveted to the fuselage. The fairing is secured
to the landing gear and telescopes up inside
Landing gear assemblies are equipped with the fillet to allow movement of the strut as the
front and rear damper assemblies. Dampers landing gear dampers compress or extend. A
absorb vertical shock to landing gear struts seal on the bottom edge of the fairing forms a
during helicopter landings. Front damper fillet between the fairing and the skid tube.
assemblies are attached to oleo attachment Fairings also have openings for cabin entry
fittings on the outboard side of the pilots steps.
Page 1/(2 blank)

321000 Revision 19
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

SERVICING
1. Landing Gear Damper Nitrogen Servicing servicing hoseschrader valve connec-
tion.
(Ref. Figure 301) Service landing gear damp-
ers equipped with schrader valve according to (6). Tighten servicing hose while nitrogen is
the following steps. flowing. Allow nitrogen pressure to
build to the valve according to dash
Do not recharge a damper if number and part number of damper
CAUTION there is evidence of fluid leak- (Ref. Table 301 or Table 302).
age. Recharging of damper will cause fur-
ther leakage of both gas and damper fluid, To prevent damage to damper or
CAUTION loss of damper fluid do not open
posing a danger to the helicopter.
schrader valve without pressurizing the
(1). Place helicopter on jacks or hoist. servicing line. If fluid loss occurs, damper
will require overhaul.
NOTE: A minimum of two dampers shall be re-
charged; either the two forward dampers, (7). Once pressure level is reached open
two aft dampers, or both forward and aft schrader valve by turning outside nut
dampers. counter clockwise, allowing system and
damper pressure to equalize for a
(2). For forward damper servicing, remove minimum of 2 minutes. If slightly over
footwell panel located in passenger pressurized, bleed off excess very
compartment (Ref. Sec. 253000). For slowly.
aft damper servicing, open engine
access doors. (8). Close schrader valve by turning the
outside nut clockwise. Torque nut to 60
(3). Remove cap from schrader valve and inch pounds (6.78 Nm) and safety
connect servicing hose, but do not wire.
tighten.
(9). Reduce charge pressure to zero, and
(4). Ensure low side of nitrogen pressure remove servicing hose. Install cap on
regulator is backed off to the unpres- schrader valve.
surized position. Slowly open the high
pressure nitrogen bottle valve. (10). Inspect damper for leakage approxi-
mately two hours after servicing. Check
(5). Slowly turn regulator control until damper extension according to
nitrogen begins to flow at the loose Table 601 of this section.
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321000 Revision 19
MAINTENANCE MANUAL
DAMPER
CAP
SCHRADER
VALVE OUTSIDE NUT
SERVICING HOSE
HIGH PRESSURE
VALVE
REGULATOR
CONTROL
Figure 301. Landing Gear Damper Nitrogen Servicing On Helicopter
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Revision 19 321000
MAINTENANCE MANUAL
Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended Landing Gear
Dampers on Helicopter
Degrees Winterized Recharge MidTemp Recharge Ambient Recharge
Pressure (1) Pressure (2) Pressure (3)
F C psi kPa psi kPa psi kPa
40 40 1,262 8,702
38 39 1,264 8,715
36 38 1,266 8,728
34 37 1,268 8,740
32 36 1,270 8,753
30 34 1,271 8,766
28 33 1,273 8,778
26 32 1,275 8,791 1,051 7,247
24 31 1,277 8,804 1,052 7,255
22 30 1,279 8,816 1,053 7,262
20 29 1,281 8,829 1,054 7,270
18 28 1,282 8,842 1,056 7,278
16 27 1,284 8,855 1,057 7,286
14 26 1,286 8,867 1,058 7,293
12 24 1,288 8,880 1,059 7,301
10 23 1,290 8,893 1,060 7,309
8 22 1,292 8,905 1,061 7,316
6 21 1,293 8,918 1,062 7,324
4 20 1,295 8,931 1,063 7,332
2 19 1,297 8,943 1,065 7,340
0 18 1,299 8,956 1,066 7,347
2 17 1,301 8,969 1,067 7,355
4 16 1,303 8,981 1,068 7,363
6 14 1,305 8,994 1,069 7,371
8 13 1,306 9,007 1,070 7,378
10 12 1,308 9,019 1,071 7,386 1,145 7,891
12 11 1,310 9,032 1,072 7,394 1,146 7,900
14 10 1,312 9,045 1,074 7,401 1,147 7,908
16 9 1,314 9,057 1,075 7,409 1,148 7,917
18 8 1,316 9,070 1,076 7,417 1,150 7,925
20 7 1,317 9,083 1,077 7,425 1,151 7,934
22 6 1,319 9,096 1,078 7,432 1,152 7,943
24 4 1,321 9,108 1,079 7,440 1,153 7,951
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321000 Revision 19
MAINTENANCE MANUAL
26 3 1,323 9,121 1,080 7,448 1,154 7,960
28 2 1,325 9,134 1,081 7,455 1,156 7,968
30 1 1,327 9,146 1,082 7,463 1,157 7,977
32 0 1,328 9,159 1,084 7,471 1,158 7,985
34 1 1,330 9,172 1,085 7,479 1,159 7,994
36 2 1,332 9,184 1,086 7,486 1,161 8,002
38 3 1,334 9,197 1,087 7,494 1,162 8,011
40 4 1,336 9,210 1,088 7,502 1,163 8,019
42 6 1,338 9,222 1,089 7,510 1,164 8,028
44 7 1,339 9,235 1,090 7,517 1,166 8,037
46 8 1,341 9,248 1,092 7,525 1,167 8,045
48 9 1,343 9,260 1,093 7,533 1,168 8,054
50 10 1,345 9,273 1,094 7,540 1,169 8,062
52 11 1,347 9,286 1,095 7,548 1,171 8,071
54 12 1,349 9,299 1,096 7,556 1,172 8,079
56 13 1,351 9,311 1,097 7,564 1,173 8,088
58 14 1,352 9,324 1,098 7,571 1,174 8,096
60 16 1,354 9,337 1,099 7,579 1,176 8,105
62 17 1,356 9,349 1,100 7,587 1,177 8,113
64 18 1,358 9,362 1,102 7,594 1,178 8,122
66 19 1,360 9,375 1,103 7,602 1,179 8,131
68 20 1,362 9,387 1,104 7,610 1,181 8,139
70 21 1,363 9,400 1,105 7,618 1,182 8,148
72 22 1,365 9,413 1,106 7,625 1,183 8,156
74 23 1,367 9,425 1,107 7,633 1,184 8,165
76 24 1,369 9,438 1,108 7,641 1,185 8,173
78 26 1,109 7,649 1,187 8,182
80 27 1,110 7,656 1,188 8,190
82 28 1,112 7,664 1,189 8,199
84 29 1,113 7,672 1,190 8,208
86 30 1,114 7,679 1,192 8,216
88 31 1,115 7,687 1,193 8,225
90 32 1,116 7,695 1,194 8,233
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Revision 19 321000
MAINTENANCE MANUAL
92 33 1,195 8,242
94 34 1,197 8,250
96 36 1,198 8,259
98 37 1,199 8,267
100 38 1,200 8,276
102 39 1,202 8,284
104 40 1,203 8,293
106 41 1,204 8,302
108 42 1,205 8,310
110 43 1,207 8,319
112 44 1,208 8,327
114 46 1,209 8,336
116 47 1,210 8,344
118 48 1,212 8,353
120 49 1,213 8,361
122 50 1,214 8,370
124 51 1,215 8,379
126 52 1,216 8,387
NOTES:
(1) For 369D26301221, and 231 extended landing gear dampers.
(2) For 369D26301241, and 251 extended landing gear dampers.
(3) For 369D26301211 extended landing gear dampers.
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321000 Revision 19
MAINTENANCE MANUAL
Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard Landing Gear
40 40 704 4,854
38 39 705 4,864
36 38 707 4,873
34 37 708 4,882
32 36 709 4,891
30 34 711 4,901
28 33 712 4,910
26 32 714 4,919 704 4,855
24 31 715 4,929 705 4,862
22 30 716 4,938 706 4,869
20 29 718 4,947 707 4,876
18 28 719 4,956 708 4,883
16 27 720 4,966 709 4,889
14 26 722 4,975 710 4,896
12 24 723 4,984 711 4,903
10 23 724 4,994 712 4,910
8 22 726 5,003 713 4,916
6 21 727 5,012 714 4,923
4 20 728 5,021 715 4,929
2 19 730 5,031 715 4,936
0 18 731 5,040 716 4,942
2 17 732 5,049 717 4,949
4 16 734 5,058 718 4,955
6 14 735 5,068 719 4,962
8 13 736 5,077 720 4,968
10 12 738 5,086 721 4,974 637 4,392
12 11 739 5,096 722 4,980 638 4,397
14 10 740 5,005 723 4,987 639 4,403
16 9 742 5,114 724 4,993 639 4,409
18 8 743 5,123 725 4,999 640 4,415
20 7 744 5,133 725 5,005 641 4,420
22 6 746 5,142 726 5,011 642 4,426
24 4 747 5,151 727 5,017 643 4,432
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Revision 19 321000
MAINTENANCE MANUAL
26 3 748 5,160 728 5,023 644 4,438
28 2 750 5,170 729 5,029 645 4,444
30 1 751 5,179 730 5,035 645 4,449
32 0 753 5,188 731 5,041 646 4,455
34 1 754 5,198 732 5,047 647 4,461
36 2 755 5,207 732 5,052 648 4,467
38 3 757 5,216 733 5,058 649 4,473
40 4 758 5,225 734 5,064 650 4,478
42 6 759 5,235 735 5,070 650 4,484
44 7 761 5,244 736 5,075 651 4,490
46 8 762 5,253 737 5,081 652 4,496
48 9 763 5,263 737 5,087 653 4,502
50 10 765 5,272 738 5,092 654 4,507
52 11 766 5,281 739 5,098 655 4,513
54 12 767 5,290 740 5,103 655 4,519
56 13 769 5,300 741 5,109 656 4,525
58 14 770 5,309 741 5,114 657 4,531
60 16 771 5,318 742 5,120 658 4,536
62 17 773 5,327 743 5,125 659 4,542
64 18 774 5,337 744 5,130 660 4,548
66 19 775 5,346 744 5,136 660 4,554
68 20 777 5,355 745 5,141 661 4,559
70 21 778 5,365 746 5,146 662 4,565
72 22 779 5,374 747 5,152 663 4,571
74 23 781 5,383 747 5,157 664 4,577
76 24 782 5,392 748 5,162 665 4,583
78 26 749 5,167 666 4,588
80 27 750 5,172 666 4,594
82 28 750 5,177 667 4,600
84 29 751 5,182 668 4,606
86 30 752 5,188 669 4,612
88 31 753 5,193 670 4,617
90 32 753 5,198 671 4,623
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321000 Revision 19
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92 33 671 4,629
94 34 672 4,635
96 36 673 4,641
98 37 674 4,646
100 38 675 4,652
102 39 676 4,658
104 40 676 4,664
106 41 677 4,670
108 42 678 4,675
110 43 679 4,681
112 44 680 4,687
114 46 681 4,693
116 47 681 4,698
118 48 682 4,704
120 49 683 4,710
122 50 684 4,716
124 51 685 4,722
126 52 686 4,727
NOTES:
(1) For 369D26300221, and 231 standard landing gear dampers.
(2) For 369D26300241, and 251 standard landing gear dampers.
(3) For 369D26300211 standard landing gear dampers.
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Revision 19 321000
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

1. Landing Gear Replacement doors, engine access doors and foot
supporting fairings.
(Ref. Figure 401)
(2). With helicopter supported by jacks,
A. Landing Gear Removal position landing gear to align struts
with openings in fuselage structure.
Consumable Materials NOTE: Check that fairing fillet guide pins en-
(Ref. Section 910000) gage fairing guide holes before positioning
Item Nomenclature struts for attachment to structure.
CM729 Tape, masking, pressure sensitive
(3). Lift and carefully position landing gear;
then place supports beneath landing
NOTE: Following procedures apply to removal gear to hold it in place.
of entire right or left landing gear assembly.
For component disassembly, refer to appli- NOTE: Install left forward damper upper bolt
cable section. For removal, two persons are with bolt head aft. Bolt direction on right
needed. side is optional.
(4). Be sure that slotted bushing (view C) is
(1). Jack up helicopter until landing gear
in place. Align lower bearing of damper
dampers are fully extended (Ref. Sec.
with mating holes in strut and install
070000). Place support beneath skid
attaching hardware.
tubes at strut locations.
(5). Align struts with mating bearings in
(2). Pull strut fairing fillet downward fuselage support fittings. Install bolt,
against spring tension and secure with slotted bushing, two washers, nut and
tape (CM729). cotter pin.
(3). Open compartment access doors for (6). Align inboard end of each brace with
access to forward brace, strut and mating bearing in fuselage supporting
damper. Disconnect brace, strut and fitting. Install slotted bushing and
damper from attachment points. attaching hardware.
(4). For access to aft landing gear attach- (7). Secure electrical bonding jumper with
ment points, open engine access doors. clamp and attaching hardware to aft
Disconnect aft brace, strut and damper strut.
from attachment points.
Do not overtighten braceto
(5). Remove clamp attaching electrical CAUTION strut hardware. Maximum per-
bonding jumper to aft strut. missible nut torque is fingertight; then
backed off to nearest cancellation for instal-
(6). Disconnect electrical wiring connections lation of cotter pin.
at upper area forward strut.
(8). If brace is detached from strut, align
(7). Remove supports from below skid and outboard end of each brace with mating
carefully remove struts, skid and holes in strut. Attach brace to strut
fairings as an assembled unit. with attaching hardware. Torque nut to
B. Landing Gear Installation 5 inchpounds (0.56 Nm) maximum.
(9). Connect wiring at forward strut.
NOTE: Following procedures apply to installa-
tion of right or left landing gear assemblies. (10). Remove skid supports, lower helicopter,
and remove jacks.
(1). For access to landing gear attachment
points, open or remove fuselage access (11). Close or replace all access doors.
Page 401
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MAINTENANCE MANUAL
FILLET
FAIRING
SKID
EXTENSION
CABIN ENTRY STEP
KNIFE SPLICE
GROUND HANDLING
FITTINGS
SAFETY
WALK TAPE
ABC BOLTS
ABRASION STRIP
SEALING COMPOUND LANDING GEAR SKID
POSITION LIGHT
ELECTRICAL HARNESS
TORQUE STRIPE
(NOTE 3)
SERVICE LOOP DAMPER
0.370.62 INCH CENTER BEAM

(9.39815.748 MM) BONDING
DIMENSION JUMPER SLOTTED
A BUSHING
(NOTE 1)
BARREL CLAMP
0.370.62 INCH
(9.39815.748 MM)
STRUT
5 IN.LB.
(0.56 NM)
TORQUE NOTE 2 MAXIMUM
STRIPE BRACE
(NOTE 3)
STRUT AND BRACE ATTACHMENT
BUSHING
(NOTE 1)
NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH
0.030 INCH (0.762 MM) (0.254 MM) TO A MAXIMUM OF 0.060 INCH (1.524 MM) ABOVE
MAXIMUM DEFECT OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
DEPTH (TYPICAL) 2. LEFT FORWARD DAMPER ATTACHING BOLT HEAD AFT FOR
REMOVAL CLEARANCE.
3. TORQUE STRIPES PAINTED CONTRASTING BLACK OR WHITE,
AS APPLICABLE.
DAMPER UPPER ATTACHMENT
G321000B
Figure 401. Landing Gear and Damper Installation
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Revision 19 321000
MAINTENANCE MANUAL
2. Landing Gear Damper Replacement 3. Landing Gear Skid Replacement
(Ref. Figure 401) (Ref. Figure 401)
A. Landing Gear Damper Removal A. Landing Gear Skid Removal

(1). If landing gear assembly is attached to
(1). Jack up or hoist helicopter on level
helicopter, jack up helicopter until
surface until landing gear skids just
dampers are fully extended (Ref. Sec.
clear resting surface.
070000). Place supports beneath skid
(2). For forward damper removal, remove tubes at strut locations.
foot well fairings located in passenger (2). Remove lower fairing from twopiece
compartment. For access for aft damper fairing assembly.
removal, open engine access doors.
(3). Remove bolts attaching forward
(3). Remove hardware (except bushings) skidtofoot assembly.
attaching forward damper assemblies
to fuselage attachment fittings and (4). Disconnect electrical connections at
landing gear struts. forward strut.
(4). Remove hardware from damper (5). Remove bolts attaching extension to
attachment points. skid adapter sleeve. Remove extension,
index plug and bearing from skid.
B. Landing Gear Damper Installation B. Landing Gear Skid Installation
(1). Jack up helicopter on level surface until
landing gear skids (Ref. Sec. 070000) Consumable Materials
just clear resting surface. (Ref. Section 910000)
Item Nomenclature
NOTE: CM318 Primer
D Always be sure that replacement damper CM420 Sealant
is correct for the helicopter. Ensure that CM425 Sealing compound
cap torque stripes will be visible for in-
spection after installation.
D If installing schrader valve equipped NOTE: Left or right replacement skids are in-
dampers, ensure fwd damper is installed terchangeable by using or removing nylon
with schrader valve facing forward and screws from side of skid at forward strut.
aft damper with schrader valve facing aft. (1). Position skid in place with aft foot
bearing installed over skid adapter
(2). Install replacement damper in upper sleeve. Connect electrical connections
and lower mounting position with for skid position light at forward strut.
attaching hardware. Ensure bushings
are in place. (2). Apply thin coating of primer (CM318) to
forward strut and skid tube mating
NOTE: Left forward damper upper bolt must be surfaces.
installed with bolt head aft. Bolt direction
on right side is optional. (3). Align mating parts and install bolts
with wet coating of zinc chromate
(3). Torque nuts to 48 55 inchpounds primer. Torque bolts 40 60 inch
(5.42 6.21 Nm) and cotter pin. pounds (4.52 6.78 Nm). Apply
sealant (CM420) to head of bolt and to
(4). Check installation for proper alignment nuts.
of torque stripes.
(4). Align skid extension with skid tube
(5). Install foot support fairings and close adapter sleeve. Coat attaching bolts
engine access doors. with primer and install while wet.
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321000 Revision 26
MAINTENANCE MANUAL
(5). Seal edges of all rigid parts on skid (e). Carefully spread fillet at trailing
with an approximate 0.060 inch (1.524 edge and remove in forward direc-
mm) fillet of sealing compound tion.
(CM425).
(3). Remove upper part of fairing as follows.
(6). Install lower fairing.
(a). Remove rivets that secure trailing
4. Landing Gear Fairing Replacement edge of fairing.
(b). Remove rivets that secure fairing to

(Ref. Figure 402)
strut bracket.
A. Landing Gear Fairing Removal (c). Use putty knife or similar thin
bladed tool to carefully pry apart
The following instructions are typical for and bonding and separate upper 5 inches
apply to all four fairing assemblies. of trailing edge; then separate fairing
from flange of lower guide.
(1). Remove lower fairing from fairing
assembly as follows. (d). Carefully spread trailing edge of
fairing and remove in forward
(a). Remove attaching hardware that direction.
secures lower fairing to two strut
brackets, and that secures trailing B. Landing Gear Fairing Installation
edge of lower fairing.
The following instructions apply to all four
(b). Carefully spread trailing edge of fairing assemblies. Where riveting is required,
lower fairing and remove in forward use rivets of type shown in Figure 802.
direction.
NOTE: Ensure that doublers between lamina- Consumable Materials

tions at trailing edge are retained for reuse. (Ref. Section 910000)
Item Nomenclature
(2). Remove fillet from upper part of fairing CM318 Primer
assembly as follows. CM411 Adhesive, epoxy
(a). Remove rivets from trailing edge of
fillet. (1). Install upper part of the fairing as
follows.
(b). Drill out one of the rivets securing
fillet to upper guide. Replace rivet (a). Assemble upper guide, pin assembly,
with sheet metal hole fastener (Cleco, inner guide half, outer guide half,
or equivalent). Repeat this step on springs and lower guide on landing
other rivets. gear strut. Install rivets with wet
primer (CM318) to secure lower
(c). Open underfloor compartment or guide to strut.
engine compartment doors for access
to strut cutout in fuselage skin. Have (b). Push guide pins into matching holes
an assistant push down on upper of lower guide. Wedge temporary
guide with suitable tool (wood dowel holding device between upper guide
or equivalent), to relieve spring and strut to keep pins engaged.
tension.
NOTE: Use two small wood blocks or any simi-
(d). With spring tension off guide, remove lar suitable means to keep springs com-
fasteners. Slowly relax dowel pres- pressed. Device used must be small enough
sure on guide until springs fully to be removed through strut cutout in skin
expand. after fillet is assembled.
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Revision 26 321000
MAINTENANCE MANUAL
NUTPLATE
RIVET
FAIRING
ASSY
FAIRING ASSY
WASHER
SCREW
SEAL
NUT
WASHER
WASHER
SCREW
COVER (EXTENDED
LANDING GEAR ONLY)
WASHER
SCREW SEAL
SEAL
G321001
Figure 402. Fairing Installation
Page 405
321000 Revision 19
MAINTENANCE MANUAL
(c). Install blind hole transfer punches (b). Carefully spread trailing edge of fillet
(two or four places, as applicable) or and position about upper guide.
fabricate suitable tools as shown Clamp lower end of fillet trailing
(Ref. Figure 802). Install tool(s) edge to upper end of fairing trailing
between opposing holes in strut edge. Clamping prevents fillet
bracket(s). movement when fillet rivets are
installed. Have an assistant remove
temporary holding device and push
(d). Carefully spread trailing edge of down on upper guide with suitable
fairing and position fairing on strut tool (wood dowel, etc). Have guide
bracket(s) and lower guide. Have an pushed down where a pencil line
drawn on guide flange is visible
assistant hold fairing in this position.
through one #40 hole in fillet. Match
drill guide and secure fillet and guide
with hole fastener (Cleco, or equiva-
(e). Back up fairing with a fiber block at lent). Repeat procedure for all rivet
transfer punch location. Using plastic locations. Remove pushing tool from
hammer, carefully strike opposite strut opening.
side of fairing to transfer hole
centers. (c). Remove one fastener at a time, and
install screws and washers (Ref.
Landing Gear Fairing Fillet Modifi-
(f). Remove fairing and check that all cation).
transfer marks appear within outline
of small laminated doublers. Drill out (d). Install screws, washers and nuts to
located holes. secure fillet trailing edge together.
(e). Check for smooth telescoping action

of fairing into fillet by manually
(g). Carefully bond fairing to lower guide
sliding fillet up and down several
(Ref. Figure 802). Use adhesive
times.
(CM411) according to container
instructions. (f). Close access doors.
(3). Install lower part of twopiece fairing

(h). Install rivets to secure fairing to as follows.
strut bracket(s).
(a). Carefully spread trailing edge of
fairing and position on upper fairing
(i). Install rivets to secure trailing edge and lower strut bracket; at correct
of fairing. position there should be 0.020
0.080 inch (0.508 2.032 mm)
compression of fairing seal against
(j). Using soft lead pencil, draw a skid tube. Have an assistant hold
continuous line along horizontal fairing at this position.
center of upper guide flange. (b). Back up fairing with fiber block at
transfer punch location. Using plastic
hammer, carefully strike opposite
(2). Install fillet as follows. side of fairing to transfer hole
centers.
(a). Drill a #40 hole in center of each 3/8 (c). Remove fairing and check that all
inch (9.525 mm) square doubler in transfer marks appear within outline
fillet. (There are six doublers in the of small laminated doublers. Drill out
fiberglass fairings.) located holes.
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Revision 26 321000
MAINTENANCE MANUAL
(d). Reinstall fairing in mounting position B. Cabin Entry Step Installation

and secure to upper and lower strut
brackets with screws and washers. Consumable Materials
(e). Secure fairing trailing edge with Item Nomenclature
attaching hardware. CM318 Primer
NOTE: Be sure doublers are installed between (1). Install replacement step on forward
laminations at trailing edge. landing gear strut, using four lockbolts
with wet primer (CM318). Four holes in
step collar must be drilled out to 0.164
5. Cabin Entry Step Replacement 0.167 inch (4.166 4.242 mm) for
installation of lockbolts. If holes are
(Ref. Figure 801) elongated, use next size larger lock-
bolts.
A. Cabin Entry Step Removal NOTE: At strut replacement, locate step by us-
ing skid centerlinetostep centerline mea-
surement of 11.78 inches (29.92 cm).
(1). Remove landing gear fairing.
(2). Install step on aft landing gear strut,
using two bolts, washers and nuts with
(2). Remove four lockbolts and step from wet primer. Torque nuts to 60 85
forward landing gear strut, or two bolts, inchpounds 6.78 9.60 Nm).
washers and nuts from aft landing gear
strut (extended gear only). (3). Install lower fairing on strut.

321000 Revision 26
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

INSPECTION/CHECK
1. Landing Gear Inspection (1). Jack helicopter until landing gear
dampers are fully extended.
(Ref. Figure 801)
(2). Remove lower fairing from twopiece
NOTE: Inspection should be performed with fairing assembly.
helicopter skids clear of ground.
(3). Inspect for dents. If dents exceed a
(1). Inspect skids, skid abrasion strips, depth of 0.20 inch (5.08 mm), they will
struts, feet, braces and fairings for require repair.
dents, cracks, loose components or
(4). Inspect for punctures and cracks.
rivets, loose nuts and for missing
hardware. (5). Perform fluorescentpenetrant inspec-
tion of all crack areas, and of those
(2). Inspect skidtofoot and foottostrut areas adjacent to all punctures. These
attachments for loose bolts. Check aft areas will require repair.
foottobearing rivet installation for
security. (6). Inspect from aft end of tube to a point
10 inches (25.40 cm) forward of aft strut
NOTE: Loose or defective bolts at forward foot for scratches and nicks. If scratches and
toskid locations requires replacement of nicks exceed a length of 0.25 inch (6.35
nutplates. mm) and a depth of 0.015 inch (0.381
mm), they will require repair.
(3). Using 10X glass and bright light,
visually inspect area at, around and (7). Inspect from forward end of tube to 10
between foottostrut attach bolts not inches (25.40 cm) forward of aft strut
covered by sealant for cracks and for scratches and nicks. If scratches and
corrosion. nicks exceed a length of 0.25 inch (6.35
mm) and a depth of 0.020 inch (0.508
NOTE: If cracks or corrosion other than light mm), they will require repair.
surface corrosion is found, replace affected
part. (8). Inspect ground handling fittings for
cracks, loose rivets, corrosion and other
(4). Inspect keel beam areas where the damage.
strut assemblies attach for loose
bearings, condition of hardware and (9). Inspect abrasion strips for damage,
strut adapters. excessive wear, and for loose bolts and
screws.
(5). Check condition of beaded seal around (10). Check skid adapter sleeve rivet attach-
edges of all rigidmounted skid tube ment for security. On early configura-
components. tions, check sleeve slots for wear and
damage.
2. Landing Gear Skid Inspection
(11). Check condition of plug installed in
(Ref. Figure 801) skid adapter sleeve.
NOTE: If landing gear assembly has not been (12). Check aft foot bearing and extension for
removed from helicopter, perform following wear, damage and corrosion. On early
steps (1). and (2). before proceeding with in- configurations, check condition of
spection. extension packing.
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321000 Revision 31
MAINTENANCE MANUAL
3. Landing Gear Strut Inspection a). Diameter of top hole (DIM. A)

should be 0.5313 inch (13.495
(Ref. Table 801 and Figure 601) mm) maximum in any direction.
b). Diameter of bottom hole (DIM.

Consumable Materials B) should be 0.50 inch (12.70
(Ref. Section 910000) mm) maximum in any direction.
Item Nomenclature
CM318 Primer 4). If no cracks are found around drag
brace attach hole in strut and hole
is not elongated, install new
(1). Check landing gear dampers for correct bushing in hole with wet primer
servicing by observing stance of (CM318).
helicopter. Check rear dampers for
correct extension and signs of leakage. 5). If either hole is oversized or
cracking is noted, rework strut
(2). Remove foot support fairings in passen- (Ref. Landing Gear Strut Drag
ger/cargo compartment and open engine Brace Hole Repair).
access doors.
(b). If no bushing is installed in drag
(3). Visually inspect strut attachment brace attach hole in strut, proceed as
points and pivot bearing for signs of follows:
fretting, wear and damage. Fretting
will be evident by gray or black materi- 1). Using 10X glass and bright light,
al around bearing, rivets or seams. inspect strut around drag brace
attach holes (top and bottom
(4). Jack helicopter until landing gear surfaces) for cracks. If any cracks
dampers are fully extended. longer than 0.030 inch (0.762 mm)
in length are noted, strut must be
(5). Shake landing gear assemblies and scrapped and serviceable strut
note any play or looseness at pivot installed.
bearings, inboard strut assembly
fittings and drag brace holes. 2). Check drag brace attach holes in
strut for elongation.
(6). If any play or looseness is noted,
remove landing gear (Ref. Landing 3). If any cracks, 0.030 inch (0.762
Gear Removal) and inspect drag brace mm) in length or less, are noted or
and strut. hole is elongated, rework strut
(Ref. Landing Gear Strut Drag
(7). Inspect strut bolt hole where drag brace Brace Hole Repair).
attaches as follows:
(8). Reinstall landing gear (Ref. Landing
(a). If bushing is installed in drag brace Gear Installation).
attach hole in strut, proceed as
follows: (9). Inspect strut for cracks or dents.
1). Check bushing for looseness then (a). If strut is cracked, scrap strut and
remove bushing. replace with serviceable strut.
2). Using 10X glass and bright light, (b). If dents in strut exceed 0.060 inch
inspect strut around drag brace (1.524 mm) depth; or, if scratches and
attach holes (top and bottom repair area depth would exceed 0.010
surfaces) for cracks. inch (0.254 mm) when measured to
surrounding unrepaired surface strut
3). Check drag brace attach holes in must be scrapped and serviceable
strut for elongation. strut installed.
Page 602
Revision 26 321000
MAINTENANCE MANUAL
DIM. A
(TOP HOLE) DAMPER
( REF )
DIM. B
(BOTTOM HOLE)
SECT BB
BOLT
WASHER
DRAG STRUT
BRACE
WASHER
COTTER PIN
NUT
STRUT AND BRACE ATTACHMENT
88779a
Figure 601. Landing Gear Strut Inspection
Page 603
321000 Revision 26
MAINTENANCE MANUAL
(10). For aircraft 369D; 001 & subs, 369E; nose up/nose down attitude, perform
0001 thru 0528, 369FF; 0001 thru 0114 damper extension check.
and 500N; 001 thru 077: Remove plug
button from underside of fairing NOTE:
assembly. Using a bright light and 10X D The landing gear damper assemblies are
magnifying glass, inspect rivet hole in to be checked at a helicopter gross weight
underside of strut for cracks. If crack is of 1925 2075 pounds (874 942 kg) at a
found, strut must be scrapped and longitudinal CG of approximately 103, ex-
serviceable strut installed. clusive of skid mounted flotation gear.
The empty weight of the 369D with full
4. Landing Gear Damper Inspection fuel, but no passengers or cargo, is 1775
1925 pounds (806 874 kg). Therefore
(Ref. Table 601, Table 602 and Figure 401) achieve the test configuration by adding
75 pounds (34 kg) of ballast to both sides
NOTE: It is normal for a thin hydraulic oil film of the cabin floor, just aft of the tail rotor
to remain on damper as a result of wiping pedals, 150 pounds (68 kg) total. Place the
contact with piston seal. Newlyinstalled helicopter on a smooth concrete or equiva-
dampers may also have slight oil seepage lent surface (not asphalt).
from oil trapped in end cap threads during D Dampers which have been modified (win-
damper assembly. Neither of these should terized) for cold weather operation are to
be considered damper leakage or cause for be checked out no more than 30F (1C)
damper replacement. above the coldest temperature at which
the helicopter is operated.
(1). Inspect for hydraulic oil leakage. If
leakage is visible, wipe oil from damper (a). Raise and lower tailboom above and
after last flight of the day. Reinspect below the normal atrest position
the following day for oil leakage. If three times. On the last cycle, allow
leakage persists, perform bench check the tailboom to slowly settle to the
(Ref. COM). atrest position.
(2). With helicopter on jacks, inspect (b). Measure and record dimension from
damper assemblies for evidence of upper end cap to upper end of barrel
bearing looseness in upper and lower on all four damper assemblies.
caps, worn bearings (excessive radial
play), loose or cracked caps and oil (c). Repeat steps (a). and (b). two more
leakage. Any misalignment of torque times.
stripes on caps, piston and barrel
indicates loosening of caps. Replace (d). Lower and raise tailboom below and
immediately and repair removed above the normal atrest position
damper. three times. On the last cycle, allow
the tailboom to slowly rise to the
atrest position.
(3). Inspect damper attaching hardware for
security. (e). Measure and record dimension from
upper end cap to upper end of barrel
NOTE: Dampers which have been modified on all four damper assemblies.
(winterized) for cold weather operation are
to be checked at not more than 30F above (f). Repeat steps (d). and (e). two more
the coldest temperature at which the heli- times.
copter is operated.
(g). Determine average extension from all
(4). Inspect landing gear dampers for six readings for each damper assem-
condition by observing stance of bly. Remove and overhaul any
helicopter (normal stance is slightly damper assembly not meeting
nose up). If stance indicates excessive dimensions (Ref. Table 601).
Page 604
Revision 26 321000
MAINTENANCE MANUAL
NOTE: If two damper assemblies fail to meet (4). Inspect safety walk tape for condition
the minimum extension (Ref. Table 601), re- and security. Replace unserviceable
place the damper having the greater tape.
amount of deflection with a known service-
able damper and repeat steps (a). thru (g). If (5). Inspect fairing seal for condition.
the original damper again fails to meet
(6). Install landing gear fairing assembly.
minimum extension requirements, replace
it with the known serviceable damper, rein-
6. Landing Gear Fairing Inspection
stall the first damper and repeat steps (a).
thru (g). This will determine whether one or (Ref. Figure 802)
both dampers require overhaul. For owners
and operators having suitable equipment, (1). Inspect fairing support brackets for
any damper not meeting minimum exten- security of attachment to strut, cracks
sion requirements can be benchchecked by and deformation.
applying a single load and measuring the
deflection when compressed. (Ref. Table 602 (2). Inspect fairingtoskid seal for deterio-
for load and compression requirements.) ration and bonding.
Dampers meeting specifications in
(3). Inspect fuselage rubbing plate for
Table 602 may be returned to service if oth-
security of bond and excessive wear.
er defects are not noted.
(4). On forward fairings (aft fairings with
5. Cabin Entry Step Inspection steps attached to struts), inspect fairing
(Ref. Figure 801) step seal for deterioration and bonding.
(1). Remove landing gear fairing assembly.

Table 601. Minimum Damper Extension
(2). Inspect steptostrut attachment for Standard Landing Gear Extended Landing Gear
loose attaching hardware by checking (in/cm) (in/cm)
for relative motion between mating
parts. Aft 3.40 / 8.64 Aft 3.20 / 8.13
(3). Inspect welded joint of step for cracks. Fwd 3.25 / 8.26 Fwd 2.90 / 7.37
Table 602. Landing Gear Damper Bench Test Requirements

Damper P/N (1) Test Load Compression Stroke
Pounds (kg) Inches (mm/cm)
369D26300 (2) 1200 (545) 0.80 (20.32 mm)
369D2630031 1320 100 (599 45) 0.80 (20.32 mm)

3780 400 (1716 182) 2.75 (6.99 cm)
369D26301 (2) 1700 (772) 0.80 (20.32 mm)
369D2630131 1900 100 (863 45) 0.80 (20.32 mm)

3950 400 (1793 182) 2.75 (6.99 cm)
NOTES:
(1) Conduct all tests at 70 2 F except as noted.
(2) Coldsoak winterized dampers at 0 3 F for 24 hours minimum before testing.

321000 Revision 26
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

REPAIRS
1. Landing Gear System Repairs NOTE: Following applies to early configuration
landing gear skids. Installation differences
(Ref. Figure 801) For more extensive repairs, for current configuration landing gear skids
refer to CSPSRM6. are noted in Figure 801.
(1). Repair scratches and nicks by smooth- (1). Remove abrasion strip. Drill out rivets
ing sharp edges. securing adapter sleeve and remove
residue from end of tube.
(2). Repair elongated, enlarged or worn
holes in strut fittings, either inboard or (2). Coat mating surface of replacement
outboard. sleeve with a thin coat of sealing
compound (CM425) and install in skid
(3). Repair bolt holes at large end of brace tube with 9.06 inch (23.012 cm) over-
that attaches to strut. hang (Ref. Figure 801).
(4). Replace strut; if cracked, if dents in (3). Drill holes for replacement rivets and
strut exceed 0.060 inch (1.524 mm) abrasion strip attachment bolt.
depth or if scratched and repaired area
depth would exceed 0.010 inch (0.254 (4). Coat replacement rivets with primer
mm) when measured to surrounding (CM318) and install while wet; Main-
unrepaired surface. tain 9.06 inch (23.012 cm) overhang
during installation.
(5). Replace defective or badly damaged
fairing. (5). Install replacement plug in sleeve 4
inches (10.16 cm) inside skid from aft
(6). Repair fairing fiberglass damage, such end). Secure in place with bead of
as small tears or punctures that do not sealant.
impair the telescoping action of the
fairing. (6). Install aft abrasion strip.
(7). Replace cracked, dented or distorted 3. Abrasion Strip Replacement

braces. (Ref. Figure 801)
(8). Repair or replace damaged skid tube.
(9). Replace center beamtolandinggear (Ref. Section 910000)
attachment bearings that exceed 0.040 Item Nomenclature
inch (1.016 mm) axial play.
CM209 Zinc chromate putty
(10). Repair loose or defective rivets securing CM318 Primer
foot to bearing; replace defective CM425 Sealing compound
bearing.
2. Skid Adapter Sleeve Replacement (1). Remove bolts securing defective

abrasion strip(s) to skid.
(Ref. Figure 801)
(2). Remove screws securing abrasion strip
to skid extension sleeve. Completely
Consumable Materials remove any residual zinc chromate
(Ref. Section 910000) putty.
Item Nomenclature
CM318 Primer (3). Apply putty (CM209) to any bare metal.
CM425 Sealing compound (4). Coat new screws or bolts for replace-
ment abrasion strip with primer
Page 801
321000 Revision 19
MAINTENANCE MANUAL
(CM318) and install while primer is edges of abrasion strip next to skid tube
still wet. with an approximate 0.060 inch (1.524
mm) bead (fillet) of sealing compound
(5). After installation, seal all of parting (CM425) to make watertight.
Table 801. Maximum Damage Limits Landing Gear Components

Dents Nicks Scratches Cracks Holes
Component in / mm in / mm in / mm in / mm in / mm
Skid tube (2) 0.200 / 5.08 0.010 / 0.254, from aft side of (Same as for No cracks 0.250 / 6.350
(1) aft strut to 10 inches (25.4 cm) nicks) (1) allowed (1) (3)
forward of the strut, with
cleanup not exceeding 0.015 /
0.381; 0.015 / 0.381 if forward
of that point to start of curved
section, with cleanup not
exceeding 0.020 / 0.508 (1)
Forward foot 0.060 / 1.524 0.060 / 1.524 0.010 / 0.254 No cracks No holes
allowed allowed
Strut 0.060 / 1.524 (1) (1) No cracks No holes

allowed allowed
Brace 0.050 / 1.270 0.010 / 0.254 0.005 / 0.127 No cracks No holes

allowed allowed
Damper assembly 0.060 / 1.524 0.010 / 0.254 0.010 / 0.254 No cracks No holes
allowed allowed
Fittings 0.010 / 0.254 0.010 / 0.254 0.010 / 0.254 No cracks No holes

allowed allowed
Aft foot 0.060 / 1.524 0.060 / 1.524 0.010 / 0.254 No cracks No holes
allowed allowed
Foot bearing 0.010 / 0.254 0.010 / 0.254 0.010 / 0.254 No cracks No Holes
allowed allowed
Indexing plug 0.040 / 1.016 0.040 / 1.016 0.040 / 1.016 No cracks No holes
allowed allowed
Skid extension 0.010 / 0.254 0.010 / 0.254 (4) 0.010 / 0.254 No cracks No holes
(4) (4) allowed allowed
NOTES:
(1) For other repair data, refer to CSPSRM6.
(2) Repair of minor skid tube damage aft of rear strut and on forward (curved) section is not required, but
surface finish must be restored.
(3) Hole must be plugged with correct size blind rivet.
(4) No damage is allowed on skid extension where skid and sleeve are attached.
Page 802
Revision 19 321000
MAINTENANCE MANUAL
BONDING JUMPER
DAMPER
CLAMP
CENTER BEAM
FAIRING BRACKET
STRUT (8 PLACES)
BOLT NUT
DAMPER
ABRASION STRIP RIVET BOLT

(TYPICAL) FOOT
GROUND HANDLING
FITTINGS SPACER
STRUT CABIN ENTRY ABRASION STRIP

BRACE SAFETY WALK
STEP
TAPE BOLT
NONSKID TAPE
NUT
SKID TUBE
FOOT
BOLT AND WASHER
BOLT NUTPLATE
(4 PLACES) (NOTE 1)
RIVNUT
SKID POSITION
LIGHT
ABRASION STRIP
WASHER
NUT
NUTPLATE FOOT
RIVNUT STEP
FORWARD BOLT
ABRASION STRIP
FOOT RIVNUT
NUTPLATE
FITTING SCREW
RIVNUT
RIVET RIVET
(TYPICAL)
LOCKWASHER
EARLY BRACKET
CURRENT
CONFIGURATION CONFIGURATION NUTPLATE
NUTPLATE/RIVNUT ATTACHMENT EXTENDED

FOR ABRASION STRIP MOUNTING LANDING GEAR G3210021A
Figure 801. Landing Gear Repairs (Sheet 1 of 2)
Page 803
321000 Revision 19
MAINTENANCE MANUAL
RIVET FOOT
SPACER BOLT
WASHER
SPACER PIN RIVET

SPACER FOOT
SCREW
RIVET
EARLY CURRENT
CONFIGURATION CONFIGURATION
RIVETS (UPPER BRACKET)

HUCKBOLTS (LOWER BRACKET)
(NOTES 3 AND 6)
(NOTES 5 AND 6)
PACKING
FAIRING
BRACKET
FOOT
SKID EXTENSION
SLEEVE
BOLT
SKID ADAPTER INDEXING
SLEEVE PLUG
COLLAR
RIVET
PIN ABRASION
DOUBLER STRIP SCREW
FORWARD FAIRING PLUG
ATTACHMENT
BEARING
EARLY CONFIGURATION
SKID
COLLAR
PLUG
FOOT NUT
WASHER
SKID ADAPTER
SLEEVE
RIVET
BEARING SPACER
NOTES:
PIN 1. BOLT AND WASHER 4 PLACES. 8 PLACES ON
SKID EARLY CONFIGURATION.
EXTENSION BOLT 2. HUCKBOLT 4 PLACES. 8 PLACES ON EARLY
SLEEVE CONFIGURATION.
SCREW
3. INSTALL NEW RIVETS WITH WET PRIMER
CURRENT CONFIGURATION (CM318).
SKID
4. 3/16 INCH (4.7625 MM) WELDING ROD OR
OTHER SUITABLE DEVICE (4 PLACES).
SKID TUBE ADAPTER AND PIVOT COMPONENTS 5. FORWARD FAIRING ONLY.
6. HUCKBOLT HEAD COUNTERSUNK INSIDE
STRUT; NO PORTION OF HEAD TO PROTRUDE
INSIDE STRUT. G3210022A
Figure 801. Landing Gear Repairs (Sheet 2 of 2)
Page 804
Revision 19 321000
MAINTENANCE MANUAL
4. Ground Handling Fitting Replacement fiberglass repair limits, the fillet and fairing
must be removed.
(Ref. Figure 801)
Consumable Materials (Ref. Section 910000)
(Ref. Section 910000) Item Nomenclature
Item Nomenclature CM418 Cement, epoxy
CM318 Primer
(1). Replace an excessively damaged lower
CM425 Sealing compound fairing.
(2). Replace damaged fairing bracket or
(1). Drill out rivets securing defective lower guide. Remove rivets, locate new
fitting. part and install blind rivets. Use next
larger size rivets if mating holes in
(2). Coat mating surfaces with zinc chro-
strut are enlarged.
mate putty (CM209) and install
replacement fitting in place. (3). Replace damaged guide/pin assembly or
guide half if guide is cracked, pins are
(3). Coat new rivets with primer (CM318) bent or badly worn or teflon pad is loose
and install while primer is wet. or badly worn.
(4). Seal edges with an approximate 0.060 (4). Replace springs that are badly worn or
(1.524 mm) inch bead of sealing rusty, or if free length is less than 8.72
compound (CM425) for waterproofing. inches.
5. Safety Walk Tape Replacement (5). Replace fillet if teflon strip is loose or
badly worn.
(Ref. Figure 801)
(6). Replace damaged strut bracket.
Remove rivets, locate new part and
Consumable Materials install blind rivets. Use next larger size
(Ref. Section 910000) rivets if mating holes in strut are
Item Nomenclature enlarged.
CM724 Tape, nonslip
(7). Replace unserviceable rubber seals; use
cement (CM418).
(1). Carefully pull or scrape away damaged 7. Landing Gear Fairing Fillet Modification
tape. The following is a procedure for modifying the
landing gear fairing fillet for easy removal and
(2). Remove all residual adhesive from skid
better access to the landing gear struts.
tube by wiping with a clean cloth
wetted by naphtha (CM220). (1). Remove fillet from upper part of fairing
assembly (Ref. Landing Gear Fairing
(3). Install new tape (CM724) and press Removal).
firmly into place. Expel air bubbles
while pressing down tape. (2). Enlarge existing holes in fairing fillets
and fillet guides to 0.220 0.230 inch
6. Landing Gear Fairing Repair (5.588 5.842 mm).
(Ref. Figure 802) Repair fairings according to (3). Install A113343 NutClips on fillet
SRM. If upper fairing is damaged beyond guides over enlarged holes.
Page 805
321000 Revision 19
MAINTENANCE MANUAL
(4). Reinstall fillets using NAS6036P (b). If no cracks are noted, install new
screws and AN960KD10L washers 369H60233 bushing in hole with
through fillet into fairing guides. wet primer.
(5). Secure trailing edge of fillet using B. Landing Gear Strut with No Bushing
NAS6036P screws, AN960KD10L Installed
washers and MS210423 nuts (washer
under screw head and nut). (1). Ream out top hole (DIM. A) to
0.53080.5313 inch (13.48213.495
(6). Finish reinstalling fillet (Ref. Landing mm) and ream out bottom hole (DIM.
Gear Fairing Installation). B) to 0.49950.50 inch (12.68712.70
mm).
8. Landing Gear Strut Drag Brace Hole
Repair (2). Perform fluorescent penetrant inspec-
(Ref. Figure 601) The following procedure is for tion of reworked areas for cracks.
repair of the bolt hole in the landing gear strut
(a). If any cracks are noted, rework strut
where the drag brace attaches. This rework is
per step (3).
for either elongated or cracks in the bolt hole
area (Ref. Landing Gear Strut Inspection). (b). If no cracks are noted, install new
369H600211 bushing in hole with
Consumable Materials wet primer (CM318).
Item Nomenclature (3). Ream out top hole (DIM. A) to
0.56080.5613 inch (12.24414.257
CM318 Primer
mm) and ream out bottom hole (DIM.
B) to 0.52950.530 inch (13.44913.462
A. Landing Gear Strut with Bushing mm).
Installed
(4). Perform fluorescent penetrant inspec-
(1). Ream out top hole (DIM. A) to tion of reworked areas for cracks.
0.56080.5613 inch (12.24414.257
mm) and ream out bottom hole (DIM. (a). If any cracks are noted, procede with
B) to 0.52950.530 inch (13.44913.462 step (5).
mm).
(b). If no cracks are found around drag
(2). Perform fluorescent penetrant inspec- brace attach hole in strut and hole is
tion of reworked areas for cracks. not elongated, install new
(a). If any cracks are noted, rework strut wet primer (CM318).
per step (3).
(5). Ream out top hole (DIM. A) to
(b). If no cracks are noted, install new
0.59080.5913 inch (15.00615.019
mm) and ream out bottom hole (DIM.
wet primer (CM318).
B) to 0.55950.560 inch (14.21114.224
(3). Ream out top hole (DIM. A) to mm).
0.59080.5913 inch (15.00615.019
mm) and ream out bottom hole (DIM. (6). Perform fluorescent penetrant inspec-
B) to 0.55950.560 inch (14.21114.224 tion of reworked areas for cracks.
mm).
(7). If crack is found, strut must be
(4). Perform fluorescent penetrant inspec- scrapped and serviceable strut
tion of reworked areas for cracks. installed.
(a). If crack is found, strut must be (8). If no cracks are noted, install new
scrapped and serviceable strut 369H60233 bushing in hole with wet
installed. primer.
Page 806
Revision 26 321000
MAINTENANCE MANUAL
CHAFING PAD
TEFLON STRIP
FILLET
(NOTE 3)
RETAINING BLOCKS RIVETS

AND CLAMP
NOTE 4
0.35 INCH (8.89 MM) TEFLON PAD

(INSIDE GUIDES) FAIRING TO LOWER GUIDE
UPPER (NOTE 1)
FAIRING 0.80 INCH (20.32 MM) UPPER GUIDE
PIN ASSEMBLY, UPPER FAIRING
INNER GUIDE HALF (NOTE 3)
LOWER FAIRING AND SPRINGS RIVET
0.35 INCH (8.89 MM)
(FWD FAIRING, 1 RIVET)
OUTER GUIDE HALF (AFT FAIRING, 2 RIVETS)
RIVETS 17/16 INCH (3.65 CM)
UPPER AND LOWER FAIRING (NOTE 2)
INSTALLATION DOUBLER (TYPICAL)
LOWER GUIDE LOWER FAIRING
(NOTE 1) (NOTE 3)
RIVETS (UPPER BRACKET)
HUCKBOLTS (LOWER BRACKET)
(NOTES 2 AND 8) 3/4 INCH (19.05 MM)
RIVET DOUBLER (TYPICAL)
(2 PLACES)
SCREW, WASHER
(4 PLACES)
HOLE
AND SEAL
(NOTES 6
AND 7)
1/2 X 3/4 INCH (
DOUBLER
FAIRING (TYPICAL)
BRACKET
FORWARD FAIRING
ATTACHMENT SKID
SKID CL
COVER (EXTENDED
LANDING GEAR ONLY) NOTES:
1. BONDED AREA; USE EPOXY ADHESIVE (CM411).
NUTPLATE 2. INSTALL NEW RIVETS WITH WET PRIMER (CM318).
(9 PLACES) 3. REFER TO CSPSRM6 FOR FIBERGLASS REPAIR.
4. CLAMP FILLET AND FAIRING TRAILING EDGES DURING INSTALLATION
OF FILLET RIVETS.
5. PENCILED CENTERLINE ALONG FLANGE.
6. 3/16 INCH (4.7625 MM) WELDED ROD OR OTHER SUITABLE DEVICE.
7. FORWARD FAIRING ONLY.
WASHER 8. HUCKBOLT HEAD COUNTERSUNK INSIDE STRUT; NO PORTION OF HEAD
(9 PLACES) TO PROTRUDE INSIDE STRUT.
RIVET
(18 PLACES) 9. DIMENSIONS FOR BRACKET AND GUIDE LOCATIONS ON NEW STRUT
SCREW INSTALLATION.
(9 PLACES) G321003A
Figure 802. Landing Gear Fairing Repairs

321000 Revision 26
MAINTENANCE MANUAL
EXTENDED LANDING GEAR

1. Extended Landing Gear Initial Installation for reuse. Remove skid assemblies with
foot assemblies attached.
The following instructions are for both left and
right landing gear assemblies. B. Standard Landing Gear Disassembly
Complete disassembly of landing gear is not
(1). Identify all components, including required; however, certain items must be
attaching hardware, or components removed.
removed for access to work area.
Protect components from damage and (1). On current configuration standard
foreign matter until installed. landing gear, disassemble as follows:
(2). Ensure all cockpit electrical switches (a). Remove bolt, washer and nut attach-
are OFF. ing aft foot assembly and skid
extension to skid tubes.
NOTE: Ensure BATTOFFEXT switch is (b). Remove bolts and washers attaching
OFF. forward foot assembly to skid tubes.
(3). Using jacking or hoisting methods, (2). On early configuration standard
raise helicopter clear of ground. landing gear, disassemble as follows:
A. Standard Landing Gear Removal (a). Remove screws and abrasion strip at
aft section of skid tubes.
Removal of complete landing gear is not (b). Remove bolts attaching skid exten-
required. sion, indexing plug and aft foot
assembly to skid tube.
(1). Open engine access doors.
(c). Remove bolts and washers attaching
(2). Remove hardware attaching aft damper forward foot assembly to skid tube.
assemblies to fuselage fittings and
landing gear struts; remove aft damper C. Extended Landing Gear Assembly
assemblies. Retain attaching hardware Extended landing gear is shipped with as
for reuse. many parts assembled as practical; however,
certain items require assembly at installation.
(3). Remove screws attaching position light
assemblies to skid assembles. Retain Early configuration forward foot assembly and
screws for reuse. Disconnect electrical skid tube have an eighthole mounting
harness and remove position light pattern; current configuration foot assembly
assemblies. and skid tube have a fourbolt mounting
pattern.
(4). Remove hardware that secures trailing
edge of forward and aft lower fairings. Consumable Materials
Remove hardware attaching lower (Ref. Section 910000)
fairings to strut assemblies. Carefully Item Nomenclature
spread trailing edge of lower fairings
CM318 Primer
and remove in forward direction.
NOTE: If preload condition prevents removal of
skid assemblies, disconnect forward foot as- (1). If early foot assembly is used with
semblies from skid assemblies to eliminate current skid tube:
preload.
(a). Drill out four rivets (48, Figure 902)
(5). Remove ABC bolts from forward and aft and remove two spacers (49) from
strut assemblies. Retain ABC hardware skid tube.
Page 901
321000 Revision 19
MAINTENANCE MANUAL
G321009
Figure 901. Extended Landing Gear Assembly (Early Configuration)
Page 902
Revision 19 321000
MAINTENANCE MANUAL

1. Bolt (MS2125004006) 30. Doubler (369D26031)
2. Washer (MS20002C4) 31. Bearing (369D260301 LH)
3. Foot assy (369D2921131 LH FWD) (369D260302 RH)
(369D2921132 RH FWD) 32. Foot (369D291133 LH AFT)
4. Screw (NAS14031) (369D291134 RH AFT)
5. Lockwasher (MS3533843) 33. Skid assy (369D292114)
6. Bracket (369H9211111) 34. Bolt (NAS1223C1)
7. Rivet (NAS1921M0403) 35. Washer (HS306222)
8. Nutplate (369H92507) 36. Abrasion strip (369H92583)
9. Rivet (CCR2645535) 37. Abrasion strip (369H6102)
10. Nutplate (NAS1068A3) 38. Tape (369D2921143)
11. Foot (369D291133 LH FWD) 39. Tube assy (369D2921145)
(369D291134 RH FWD) 40. Screw (NAS1190C3P3)
12. Bolt (NAS1223C1) 41. Rivet (NAS1921M0403)
13. Washer (HS306222) 42. Nutplate (369H92507)
14. Abrasion strip (369H6102) 43. Rivet (NAS1919M0403)
15. Screw (NAS56HK36) 44. Fitting (369A61073)
16. Bolt (NAS1223C8P) 45. Rivet (NAS1399D44)
17. Extension assy (369D26038) 46. Spacer (369A61007)
18. Index plug (369D26037) 47. Spacer (369A61005)
19. Foot assy (369D292111101 LH AFT) 48. Rivet (NAS1399C53)
(369D292111102 RH AFT) 49. Rivet (NAS1399C52)
20. Screw (NAS14031) 50. Rivet (NAS1398C53)
21. Lockwasher (MS3533843) 51. Rivet (NAS1398C52)
22. Bracket (369H9211111) 52. Plug (369D26040)
23. Rivet (ML5100M43) 53. Adapter sleeve (369D26032)
24. Nutplate (369H92507) 54. Tube (369D292115)
25. Rivet (MS20605AD3C3) 55. Nut (MS210455)
26. Nutplate (NAS1068A3) 56. Washer (AN960KD513)
27. Pin rivet (HL3375K8A6) 57. Bolt (NAS130536)
28. Packing (H53113E142) 58. Step assy (369D292028)
29. Rivet (MS20426AD4) 59. Screw (10304288M)
Page 903
321000 Revision 19
MAINTENANCE MANUAL
G321010
Figure 902. Extended Landing Gear Assembly (Current Configuration)
Page 904
Revision 19 321000
MAINTENANCE MANUAL

1. Bolt (MS2125004006) 30. Nutplate (NAS1068A3)
2. Washer (MS20002C4) 31. Pin rivet (HL3375K8A6)
3. Foot assy. (369D292113103 LH FWD) 32. Pin rivet (HL3375K8A6)
(369D292113104 RH FWD) 33. Bearing (369D260101 LH)
(369D292113101 LH FWD) (369D260102 RH)
(369D292113102 RH FWD) 34. Foot (369D2921135 LH AFT)
4. Screw (NAS14031) (369D2921136 RH AFT)
5. Screw (NAS14035) 35. Skid assy (369D292114101/103)
6. Lockwasher (MS3533843) 36. Bolt (NAS1223C1 (101 assy))
7. Bracket (369H9211111) (NAS1223C4 (103 assy))
8. Rivet (NAS1921M0403) 37. Washer (HS306222)
9. Nutplate (369H92507) 38. Abrasion strip (369H92583)
10. Rivnut (NAS1329C3KB180) 39. Tape (369D2921143)
11. Rivnut (CCR2645535) 40. Tube assy (369D2921147/9)
12. Nutplate (NAS1068A3) 41. Screw (NAS1190C3P3 (101 assy))
13. Foot (369D2921135 LH FWD) (NAS1130C3P8 (103 assy))
(369D2921136 RH FWD) 42. Rivet (NAS1921M0403)
14. Bolt (NAS1223C1 (101 assy)) 43. Nutplate (369H92507)
(NAS1223C5 (103 assy)) 44. Rivnut (C2R19471)
15. Washer (HS306222) 45. Rivnut (C2R19472)
16. Bolt (NAS110444) 46. Rivet (NAS1919M0403)
17. Spacer (369D26013) 47. Fitting (369A61073)
18. Nut (NAS210424) 48. Rivet (NAS1399D44)
19. Abrasion strip (369H6102) 49. Spacer (369D26014)
20. Extension assy (369D26045) 50. Spacer (369D26015)
21. Foot assy (369D292111105 LH AFT) 51. Rivet (NAS1399C53)
(369D292111103 LH AFT) 53. Rivet (NAS1398C53)
22. Screw (NAS14031) 55. Plug (369D26040)
23. Screw (NAS14035) 56. Adapter sleeve (369D26012)
24. Lockwasher (MS3533843) 57. Tube (369D292115)
25. Bracket (369H9211111) 58. Nut (MS210455)
26. Rivet (ML5100M43) 59. Washer (AN960KD516)
27. Nutplate (369H92507) 60. Bolt (NAS130536)
28. Rivnut (NAS1329C3KB180) 61. Step (369D292028)
29. Rivet (MS20605AD3C3) 62. Screw (10304288M)
Page 905
321000 Revision 19
MAINTENANCE MANUAL
(b). Apply primer (CM318) to replace- (b). Coat screw (15) and bolts (16) with
ment spacers (47, Figure 901) and primer and install.
install into skid tube with four
NAS1399D44 rivets. (3). Coat mating surface of abrasion strip
and hardware with primer.
(c). Position foot assembly on skid tube
and locate center four holes. (a). Position abrasion strip (14) on aft
section of skid tube.
(d). Mark holes and drill the needed (b). Install abrasion strip using bolts (12)
0.254 0.260 inch (6.452 6.604 and washers (13).
mm) holes as required.
(c). Seal mating edge of abrasion strip
(2). If current foot assembly is used with with 0.060 inch (1.524 mm) bead of
early skid tube: sealing compound (CM425).
(a). Fill center four holes with sealing E. Current Configuration Extended Landing
compound (CM425). Gear Skid Tube Assembly Buildup
(3). Attach extended wire harness to (Ref. Figure 903)

position light and install light in
forward end of skid tube (Ref. Consumable Materials
Figure 903) using screws retained from (Ref. Section 910000)
standard landing gear. Item Nomenclature
CM318 Primer
D. Early Configuration Extended Landing
Gear Assembly Buildup CM425 Sealing compound
(Ref. Figure 901)

(1). Coat mating surface of forward foot
assembly (3) and skid tube (57) with
Consumable Materials primer (CM318).
Item Nomenclature (a). Position forward foot assembly on
skid tube.
CM318 Primer
CM425 Sealing compound (b). Apply primer to bolts (1) and washers
(2) and install; torque bolts to 80
100 inchpounds (9.04 11.30
(1). Coat mating surface of forward foot Nm).
assembly (3) and skid tube (54) with
primer (CM318). (2). Coat mating surfaces of aft foot assem-
bly (21) and extension (20) with primer.
(a). Position forward foot assembly on Position extension and aft foot assem-
skid tube. bly on adapter sleeve (56).
(3). Coat mating surface of abrasion strip
(b). Apply primer to bolts (1) and washers (19) and hardware with primer and
(2) and install; torque bolts to 80 position on extension (20).
100 inchpounds (9.04 11.30
Nm). (a). Install aft foot assembly (21), exten-
sion (20) and abrasion strip (19)
(2). Coat mating surfaces of extension (17), using bolts (14 and 16), washers (15),
indexing plug (18) and aft foot assembly spacer (17) and nut (18).
(32) with primer.
(b). Seal mating edge of abrasion strip
(a). Position indexing plug, aft foot with 0.060 inch (1.524 mm) bead of
assembly and extension on skid tube. sealing compound (CM425).
Page 906
Revision 19 321000
MAINTENANCE MANUAL
F. Extended Landing Gear Installation (6). Route extended wire harness from
position light through forward foot
(Ref. Figure 901) assembly.
Consumable Materials (a). Attach wire with splice (CM812);

(Ref. Section 910000) cover splice with silicon tube
Item Nomenclature (CM612) and tie tube with strap
(CM703).
CM318 Primer
CM420 Sealant (b). Cover entire length of extended
CM612 Tube, silicone electrical harness with vinyl sleeve
CM613 Sleeve, vinyl (CM613).
CM703 Tie strap (7). Install extended landing gear aft
CM812 Splice, knife damper assemblies using serviceable
N/A Wire, AWG 20, 47108B20 hardware removed from standard
landing gear (Ref. Landing Gear
Damper Replacement).
(1). Align foot and skid assembly with strut
assembly. (8). Apply 0.060 inch (1.524 mm) bead of
sealant (CM420) to mating edge of foot
(2). Slide foot assembly into strut assembly. assemblies and strut assemblies.
(3). Coat ABC bolts with primer (CM318).
(9). Install fairings (Ref. Landing Gear
(4). While primer is wet, install ABC bolts; Fairing Replacement).
torque bolts to 40 60 inchpounds
(4.52 6.78 Nm). G. Weight and Balance
(5). Seal ABC bolts with sealant (CM420). Weight and balance changes that result from
installation of extended landing gear are listed
NOTE: Leave a minimum of one full service in Table 901. After installation of extended
loop in electrical harness to ensure that ten- landing gear, incorporate changes to helicopter
sion is not applied to position lights, if weight and balance record as instructed in
installed. Section 081000.
Weight Arm Moment
lbs (kg) in. (cm) in.lb/100 (kg mm/100)
Added +94 (+42.638) 92.3 (234.44) +86.8 (+10000.04)
Removed 73 (33.112) 97.0 (246.38) 70.8 (815.70)
Change +21 (+9.525) 76.0 (193.04) +16.0 (+184.34)
Page 907
321000 Revision 19
MAINTENANCE MANUAL
AFT DAMPER ASSEMBLY

(BLACK)
STRUT
(TYPICAL)
LOWER FAIRING
ASSEMBLY
FOOT ASSEMBLY
(TYPICAL)
SEALING
COMPOUND
KNIFE SPLICE ABC BOLT
LOWER FAIRING
STEP
ASSEMBLY
SEALING COMPOUND
ABC BOLT
SEALING COMPOUND
SKID ASSEMBLY
SERVICE LOOP
POSITION
LIGHT
ELECTRICAL HARNESS
G321008
Figure 903. Extended Landing Gear
Page 908
Revision 19 321000
MAINTENANCE MANUAL
Section
321060
Landing Gear
System (600N)
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

1. Landing Gear System structure. Aft damper assemblies are attached
to oleo support fittings in the engine compart-
The landing gear consists of two strut ment.
mounted, shockdampened skids aligned
longitudinally along the helicopter fuselage. The damper assemblies are approximately
Both right and left skids pivot as the damper 12.19 (31 cm) inches long when extended and
assemblies extend and retract. Replaceable 8.94 (22.7 cm) inches long when compressed.
abrasion strips are installed on each skid to The dampers are nozzletype and consist of a
retard wear on hard surfaces. barrel, upper and lower mounting cap and a
piston.
A. Skid
Damper exterior surfaces are painted white for
Landing gear skids provide helicopter rest the standard gear and black for the extended
mounts. Skid tubes are constructed from gear as an aid to identification and for surface
seamless, extruded aluminum alloy tubing. protection.
Abrasion strips attached to undersides of skid
tubes retard wear and damage. Ground A damper must be replaced if damaged, or if
handling bolts, bolted through the skid tubes, loss of hydraulic oil occurs.
are the ground handling attach points. An
adapter sleeve at the aft end of skid tube D. Entry Step
provides a nonrigid mount for the aft foot Entry steps mounted on the forward landing
bearing and skid extension. gear struts allow for easy access into the cabin.
B. Strut The landing gear step is covered with nonskid
tape and attached to the landing gear strut
The landing gear struts attach to the fuselage with rivets.
center beam. Landing gear braces between the
landing gear strut and fuselage center beam E. Fairing
prevent shearing of the strut and keep the Aluminum fairings on each strut reduce
strut in alignment with the landing gear. At aerodynamic drag during flight. The fairings
the lower ends of the struts, footshaped extend from the fuselage to the skids to form
components attach the landing gear skids to streamlined enclosures for the landing gear
the struts. Feet for the aft strut are bearing struts. Each fairing assembly is constructed of
mounted to provide a nonrigid and pivotal three main parts: a fillet, an mid and lower
mount. fairing. The fillet is springloaded to remain in
C. Damper firm contact with a plastic rubbing plate that
is bonded and riveted to the fuselage. The
Landing gear assemblies are equipped with fairing is secured to the landing gear and
front and rear damper assemblies. Dampers telescopes up inside the fillet to allow move-
absorb vertical shock to landing gear struts ment of the strut as the landing gear dampers
during helicopter landings and help prevent compress or extend. A seal on the bottom edge
ground resonance. Front damper assemblies of the fairing forms a fillet between the fairing
are attached to oleo attachment fittings on the and the skid tube. Forward fairings also have
outboard side of the pilots compartment seat openings for cabin entry steps.
Page 1/(2 blank)

321060 Revision 19
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

SERVICING
1. Landing Gear Damper Nitrogen Servicing servicing hoseschrader valve connec-
tion.
(Ref. Figure 301) Service landing gear damp-
ers equipped with schrader valve according to (6). While the nitrogen is still flowing,
the following steps. tighten servicing hose. Allow nitrogen
pressure to build to the value according
Do not recharge a damper if to part and dash number of damper
CAUTION there is evidence of fluid leak- (Ref. Table 401).
age. Recharging of damper will cause fur-
To prevent damage to damper or
ther leakage of both gas and damper fluid, CAUTION loss of damper fluid do not open
posing a danger to the helicopter.
schrader valve without pressurizing the
(1). Place helicopter on jacks or hoist and servicing line. If fluid loss occurs, damper
elevate until dampers are fully ex- will require overhaul.
tended.. (7). Once pressure level is reached, open
(2). For forward damper servicing, remove schrader valve by turning outside nut
foot support fairings located in passen- counter clockwise. Allow system and
ger compartment. For aft damper damper pressure to equalize for a
servicing, open engine access doors. minimum of 2 minutes. If slightly over
pressurized, bleed off excess very
(3). Remove cap from schrader valve and slowly.
connect servicing hose, but do not (8). Close schrader valve by turning the
tighten. outside nut clockwise. Torque nut to 50
60 inch pounds (5.65 6.78 Nm).
(4). Ensure low side of nitrogen pressure
Remove servicing hose and install valve
regulator is backed off to the unpres-
cap fingertight.
surized position. Slowly open the high
pressure nitrogen bottle valve. (9). Remove aircraft from jacks or hoist.
(5). Slowly turn regulator control until (10). Inspect damper for leakage approxi-
nitrogen begins to flow at the loose mately two hours after servicing.
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321060 Revision 19
MAINTENANCE MANUAL
DAMPER
CAP
OUTSIDE NUT
SERVICING HOSE
SCHRADER VALVE
HIGH PRESSURE VALVE
REGULATOR CONTROL
6G32045
Figure 301. Landing Gear Damper Nitrogen Servicing On Helicopter
Page 302
Revision 19 321060
MAINTENANCE MANUAL
Table 301. Nitrogen Recharge Pressure

Ambient Temperature 600N605033 600N605031
F ( C) Psig (kPa) Psig (kPa)
40 (40) 263 (1813) 151 (1041)
35 (37) 268 (1848) 153 (1055)
30 (34) 272 (1875) 156 (1076)
25 (32) 277 (1910) 158 (1089)
20 (29) 281 (1937) 161 (1110)
15 (26) 286 (1972) 163 (1124)
10 (23) 291 (2006) 166 (1145)
5 (21) 295 (2034) 169 (1165)
0 (18) 300 (2068) 171 (1179)
5 (15) 305 (2103) 174 (1200)
10 (12) 310 (2137) 177 (1220)
15 (9) 315 (2172) 179 (1234)
20 (7) 320 (2206) 182 (1255)
25 (4) 325 (2241) 185 (1276)
30 (1) 330 (2275) 188 (1296)
35 (2) 335 (2310) 191 (1317)
40 (4) 340 (2344) 194 (1338)
45 (7) 345 (2379) 197 (1358)
50 (10) 351 (2420) 199 (1372)
55 (13) 356 (2455) 202 (1393)
60 (16) 361 (2489) 205 (1413)
65 (18) 367 (2530) 208 (1434)
70 (21) 372 (2565) 211 (1455)
75 (24) 378 (2606) 215 (1482)
80 (27) 383 (2641) 218 (1503)
85 (29) 389 (2682) 221 (1524)
90 (32) 395 (2723) 224 (1544)
95 (35) 400 (2758) 227 (1565)
100 (38) 406 (2799) 230 (1586)
105 (41) 412 (2841) 234 (1613)
110 (43) 418 (2882) 237 (1634)
115 (46) 424 (2923) 240 (1655)
120 (49) 430 (2965) 244 (1682)
125 (52) 436 (3006) 247 (1703)

321060 Revision 19
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

1. Landing Gear Strut Replacement (10). Gently work strut around bearing in
fuselage support fitting and remove.
(Ref. Figure 401)
B. Landing Gear Strut Installation
Consumable Materials (1). For access to forward brace, strut and
(Ref. Section 910000) damper, open compartment access
Item Nomenclature doors.
CM318 Primer (2). For access to aft landing gear attach-
CM729 Tape, masking, pressure sensitive ment points, open engine access doors.
NOTE: New bushings must be installed when
A. Landing Gear Strut Removal installing struts. Torquing of the bolt will
press bushing into place.
NOTE: For component disassembly, refer to
applicable section. For removal, two persons (3). Gently work struts around bearings in
are needed. fuselage support fittings.
(1). Jack up or hoist helicopter until skid (4). Install attaching hardware with new
assemblies clear surface by 10 20 bushing coated with wet primer
inches (25 50 cm) (Ref. Sec. (CM318).
070000). (5). Torque nut to 85 110 inchpounds
(9.60 12.43 Nm) plus drag torque
(2). Remove skid assemblies (Ref. Landing and install cotter pin.
Gear Skid Replacement).
(6). Check for minimum 0.010 inch (0.254
(3). Pull strut fairing fillet downward mm) gap between washer and airframe
against spring tension and secure with clevis at slotted bushing.
tape (CM729).
NOTE: Install forward damper upper bolts
NOTE: Bushings must be removed from strut with bolt heads facing aft. Install all other
to enable strut to clear bearing in fuselage damper bolts with bolt head facing forward.
support fittings.
(7). Install damper (Ref. Landing Gear
(4). For access to forward brace, strut and Damper Replacement).
damper, open compartment access
doors. (8). Align inboard end of each brace with
mating bearing in fuselage supporting
(5). For access to aft landing gear attach- fitting and install attaching hardware.
ment points, open engine access doors. (9). Torque nut to 60 85 inchpounds
(6). Disconnect brace and damper from
and install cotter pin.
strut.
(7). Remove hardware from strut pivot mm) gap between washer and airframe
point. clevis at slotted bushing.
(8). Use an ezyout to pull both bushings (11). Secure electrical bonding jumpers to
from strut clevis at pivot point. airframe.
(9). Remove electrical bonding jumper (12). Align outboard end of each brace with
attaching aft strut to airframe. mating holes in strut.
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321060 Revision 19
MAINTENANCE MANUAL
Do not overtighten braceto (2). Install replacement damper in upper

CAUTION strut hardware. and lower mounting position with
attaching hardware. Ensure bushings
(13). Attach brace to strut with attaching are in place.
hardware.
(14). Torque nut to 2 10 inchpounds NOTE: Install forward damper upper bolts
(0.226 1.13 Nm) plus drag torque with bolt heads facing aft. Install all other
and install cotter pin. damper bolts with bolt head facing forward.
(15). Reinstall skid assemblies (Ref. Landing

Gear Skid Replacement). (3). Align forward upper damper bearing
with airframe and install attaching
(16). Remove skid supports, lower helicopter, hardware.
and remove jacks.
(17). Close or replace all access doors. (4). Torque nuts to 60 85 inchpounds
2. Landing Gear Damper Replacement and install cotter pin.
(Ref. Figure 401)

A. Landing Gear Damper Removal mm) gap between washer and airframe
clevis at slotted bushing.
(1). Jack up or hoist helicopter on level
surface until landing gear skids just
clear resting surface. (6). Align aft upper damper bearing with
airframe and install attaching hard-
(2). For forward damper removal, remove ware.
footwell fairings located in passenger
compartment. For access for aft damper (7). Torque nuts to 95 110 inchpounds
removal, open engine access doors. (10.73 12.43 Nm) plus drag torque
(3). Remove hardware (except bushings) and install cotter pin.
attaching damper assemblies to
fuselage attachment fittings and (8). Check for minimum 0.010 inch (0.254
landing gear struts. mm) gap between washer and airframe
clevis at slotted bushing.
(4). Remove damper from aircraft.
B. Landing Gear Damper Installation (9). Align lower bearing of damper (forward
and aft) with mating holes in strut and
(1). Jack up or hoist helicopter on level install attaching hardware.
surface until landing gear skids (Ref.
Sec. 700) just clear resting surface.
(10). Torque nut to 95 110 inchpounds
NOTE: (10.73 12.43 Nm) plus drag torque
D Always be sure that replacement damper and install cotter pin.
is correct for the helicopter.
D Check for proper alignment of cap torque (11). Check for minimum 0.010 inch (0.254
stripes before installation. mm) gap between washer and airframe
D Install aft dampers with schrader valves clevis at slotted bushing.
facing aft.
D Install fwd dampers with schrader valves (12). Install footwell fairings and close
facing forward. engine access doors.
Page 402
Revision 26 321060
MAINTENANCE MANUAL
REF. AFT
FOOT ASSEMBLY
LANDING GEAR
SKID
REF. FRONT ABRASION

FOOT ASSEMBLY STRIP
ABRASION
STRIP
ABRASION
STRIP
ABRASION
STRIP
AFT BRACE
ASSEMBLY
AFT DAMPER
ASSEMBLY
FUSELAGE
FITTING FRONT DAMPER
ASSEMBLY
AFT STRUT
ASSEMBLY
BONDING
JUMPER
FRONT STRUT
ASSEMBLY
FRONT BRACE
ASSEMBLY
REF. AFT
REF. AFT BRACE ASSEMBLY
DAMPER ASSEMBLY
REF. FRONT REF. AFT

DAMPER ASSEMBLY STRUT
ASSEMBLY
REF. FRONT
MID FAIRING
STRUT
ASSEMBLY
MID FAIRING
BOLT
STEP WASHER LOWER FAIRING
ASSEMBLY NUT
BOLT LOWER FAIRING
WASHER
NUT
6G32046B
Figure 401. Landing Gear and Damper Installation
Page 403
321060 Revision 34
MAINTENANCE MANUAL
3. Landing Gear Skid Replacement (b). Open underfloor compartment or

engine compartment doors for access
(Ref. Figure 401) to strut cutout in fuselage skin. Have
an assistant push down on upper
A. Landing Gear Skid Removal guide with suitable tool (wood dowel
or equivalent), to relieve spring
(1). Jack up or hoist helicopter until skid tension.
assemblies clear surface by 10 20
inches (Ref. Sec. 0700). (c). With spring tension off guide, remove
screws attaching fillet to upper guide.
(2). Remove mid and lower fairings. Slowly relax dowel pressure on guide
until springs fully expand.
(3). Remove bolts attaching forward and aft (d). Carefully spread fillet at trailing
feet to forward and aft struts. edge and remove in forward direc-
tion.
(4). Simultaneously, slide front and rear
feet from struts. (3). Remove mid fairing as follows.
B. Landing Gear Skid Installation (a). Remove hardware that secure

trailing edge of mid fairing.
(1). Simultaneously, slide front and rear (b). Remove hardware that secure fairing
feet onto struts. to strut bracket.
(2). Install bolts attaching forward and aft (c). Carefully spread trailing edge of
feet to forward and aft struts; torque fairing and remove in forward
bolts to 95 110 inchpounds (10.73 direction.
12.43 Nm) plus drag torque.
B. Landing Gear Fairing Installation
(3). Install mid and lower fairings. (Ref. Figure 402 and Figure 403) Following
instructions apply to all four fairing assem-
4. Landing Gear Fairing Replacement blies.
A. Landing Gear Fairing Removal (1). Install mid fairing as follows.

(a). Assemble upper guide, pin assembly,
(Ref. Figure 402 and Figure 403) The following inner guide half, outer guide half,
instructions are typical for and apply to all springs and lower support on landing
four fairing assemblies. gear strut (guide pins must be
installed through matching holes of
(1). Remove lower fairing from fairing lower guide).
assembly as follows.
(b). Wedge temporary holding device
(a). Remove attaching hardware that between upper guide and strut to
secures lower fairing to two strut keep pins engaged.
brackets, and that secures trailing
edge of lower fairing. NOTE: Use two small wood blocks or any simi-
lar suitable means to keep springs com-
(b). Carefully spread trailing edge of pressed. Device used must be small enough
lower fairing and remove in forward to be removed through strut cutout in skin
direction. after fillet is assembled.
(c). Carefully spread trailing edge of
(2). Remove fillet from upper fairing fairing and position fairing on strut
assembly as follows. bracket(s) and lower guide.
(a). Remove hardware that secure (d). Install hardware in top hole of
trailing edge of fillet. trailing edge of mid fairing.
Page 404
Revision 20 321060
MAINTENANCE MANUAL
(2). Install fillet as follows. (e). Check for smooth telescoping action
of fairing into fillet by manually
sliding fillet up and down several
(a). Carefully spread trailing edge of fillet times.
and position about upper guide.
(f). Close access doors.
(b). Have an assistant remove temporary (3). Install lower fairing as follows.
holding device and push down on
upper guide with suitable tool (wood (a). Carefully spread trailing edge of
dowel, etc). fairing and position under the mid
fairing and over the lower strut
bracket.
(c). Install hardware securing fillet to
upper guide. (b). Secure to upper and lower strut
brackets with hardware.
(d). Install hardware to secure fillet (c). Secure fairing trailing edge with
trailing edge together. attaching hardware.
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321060 Revision 19
MAINTENANCE MANUAL
AFT FILLET
ASSEMBLY
FORWARD
FILET ASSEMBLY
MID FAIRING
STRUT
AFT STRUT
MID FAIRING
SEAL
LOWER FAIRING
FLAP
LOWER FAIRING
SCREW
WASHER
A NUT (5 PL)
SCREW A
WASHER A
(2 PL) A
SCREW
WASHERS (2 EA) SCREW
NUT (5 PL) WASHERS (2 EA) (2 PL)
FORWARD LEFT SIDE SHOWN AFT LEFT SIDE SHOWN

FORWARD RIGHT SIDE IS OPPOSITE AFT RIGHT SIDE IS OPPOSITE
BRACKET
ASSEMBLY
SCREW
WASHER (2 PL)
FAIRING ASSEMBLY
STRUT RIVET
FLAP
(AFT FAIRING ONLY)
SECTION A A
6G32047A
Figure 402. Fairing Installation
Page 406
Revision 19 321060
MAINTENANCE MANUAL
NAS6039P SCREW
AN9703 WASHER
600N60811
WASHER (RUBBER)
NAS6039P SCREW
AN9703 WASHER
600N60811
LOWER FORWARD FAIRING WASHER (RUBBER)
600N60811 EARLY CONFIGURATION
WASHER (RUBBER)
NAS6039P SCREW
AN9703 WASHER
LOWER FORWARD FAIRING 600N60811

CURRENT CONFIGURATION WASHER (RUBBER)
NAS6039P SCREW
AN9703 WASHER
600N60811
WASHER (RUBBER)
600N60811
WASHER (RUBBER)
UPPER FORWARD FAIRING

ALL CONFIGURATIONS
600N60811
AFT FAIRING WASHER (RUBBER)
88757
Figure 403. Landing Gear Rubber Washer Locations

321060 Revision 20
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

INSPECTION/CHECK
1. Landing Gear Inspection (2). Remove lower fairing from twopiece
fairing assembly.
(Ref. Figure 401)
(3). Inspect skid for dents. If dents exceed a
NOTE: If landing gear is installed, perform in- depth of 0.20 inch (5.08 mm), they will
spection with helicopter skids clear of require repair.
ground.
(4). Inspect for punctures and cracks.
(1). Inspect skids, skid abrasion strips, (5). Perform fluorescentpenetrant inspec-
struts, feet, braces and fairings for tion of all crack areas, and of those
dents, cracks, loose components or areas adjacent to all punctures. These
rivets, loose nuts and for missing areas will require repair.
hardware.
(6). Inspect from aft end of tube to a point
(2). Inspect skidtofoot and foottostrut 10 inches (25.4 cm) forward of aft strut
attachments for loose bolts. Check aft for scratches and nicks.
foottobearing rivet installation for
security. (7). Inspect from forward end of tube to 10
inches (25.4 cm) forward of aft strut for
(3). Using 10X glass and bright light, scratches and nicks. If scratches and
visually inspect area at, around and nicks exceed a length of 0.25 inch (6.35
between foottostrut attach bolts not mm) and a depth of 0.020 inch (0.508
covered by sealant for cracks and mm), they will require repair.
corrosion.
(8). Inspect abrasion strips for minimum
NOTE: If cracks or corrosion other than light thickness of 0.040 inch (1 mm), damage
surface corrosion is found, replace affected and for loose bolts and screws.
part.
(9). Check skid extension rivet attachment
for security.
(4). Inspect keel beam areas where the
strut assemblies attach for loose (10). Check condition of plug installed in
bearings, condition of hardware and skid extension.
strut adapters.
(11). Check aft foot bearing and extension for
(5). Check condition of beaded seal around wear, damage and corrosion.
edges of all rigidmounted skid tube
components. 3. Landing Gear Strut Inspection
2. Landing Gear Skid Inspection (Ref. Table 801)
(1). Repair elongated, enlarged or worn

(Ref. Figure 401) holes in strut, either inboard or out-
board (Ref. SRM).
NOTE: If landing gear assembly has not been
removed from helicopter, perform following (2). Replace strut if cracked; if dents in
steps (1). and (2). before proceeding with in- strut exceed 0.060 inch (1.524 mm)
spection. depth; or, if scratches and repair area
depth would exceed 0.010 inch (0.254
(1). Jack helicopter until landing gear mm) when measured to surrounding
dampers are fully extended. unrepaired surface.
Page 601
321060 Revision 31
MAINTENANCE MANUAL
4. Landing Gear Damper Inspection (d). Lower and raise tailboom below and
above the normal atrest position
(Ref. Table 601 and Figure 401) three times. On the last cycle, allow
the tailboom to slowly rise to the
NOTE: It is normal for a thin hydraulic oil film atrest position.
to remain on damper as a result of wiping (e). Measure and record dimension from
contact with piston seal. Newlyinstalled bottom of upper end cap to top of
dampers may also have slight oil seepage barrel on all four damper assemblies.
from oil trapped in end cap threads during
damper assembly. Neither of these should (f). Repeat steps (d). and (e). two more
be considered damper leakage or cause for times.
damper replacement. (g). Determine average extension from all
six readings for each damper assem-
(1). Inspect for hydraulic oil leakage. If bly. Remove and overhaul any
leakage is visible, wipe oil from damper damper assembly not meeting
after last flight of the day. Reinspect dimensions (Ref. Table 601).
the following day for oil leakage. If NOTE: If two damper assemblies fail to meet
leakage persists, replace damper. the minimum extension (Ref. Table 601), re-
place the damper having the greater
(2). With helicopter on jacks, inspect amount of deflection with a known service-
damper assemblies for evidence of able damper and repeat steps (a). thru (g). If
bearing looseness in upper and lower the original damper again fails to meet
caps, worn bearings (excessive radial minimum extension requirements, replace
play), loose or cracked caps and oil it with the known serviceable damper, rein-
leakage. Any misalignment of torque stall the first damper and repeat steps (a).
stripes on caps, piston and barrel thru (g). This will determine whether one or
indicates loosening of caps. Replace both dampers require overhaul. For owners
immediately and repair removed and operators having suitable equipment,
damper. any damper not meeting minimum exten-
sion requirements can be benchchecked.
(3). Inspect damper attaching hardware for Dampers meeting specifications may be re-
security. turned to service if other defects are not
noted.
NOTE: The landing gear damper assemblies 5. Forward Cabin Entry Step Inspection
are to be checked at a helicopter gross
weight of 2130 2230 pounds (967 1012 (1). Remove landing gear fairing assembly.
kg) at a longitudinal CG of 94 1, exclusive (2). Inspect steptostrut attachment for
of skid mounted flotation gear. Place the he- loose attaching hardware by checking
licopter on a smooth concrete or equivalent for relative motion between mating
surface (not asphalt). parts.
(a). Raise and lower tailboom above and (3). Inspect welded joint of step for cracks.
below the normal atrest position (4). Inspect safety walk tape for condition
three times. On the last cycle, allow and security. Replace unserviceable
the tailboom to slowly settle to the tape.
atrest position.
(5). Install landing gear fairing assembly.
(b). Measure and record dimension from 6. Landing Gear Fairing Inspection
bottom of upper end cap to top of
barrel on all four damper assemblies. (Ref. Figure 402)
(1). Inspect fairing support brackets for
(c). Repeat steps (a). and (b). two more security of attachment to strut, cracks
times. and deformation.
Page 602
Revision 19 321060
MAINTENANCE MANUAL
(2). Inspect fairing seals for deterioration Table 601. Minimum Damper Extension
and bonding.
(3). Inspect fuselage rubbing plate for inches (cm)
security of bond and excessive wear.
Fwd 1.60 (4.06)
(4). Inspect rubber washers for cracks or
deterioration. Aft 1.71 (4.34)

321060 Revision 22
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

REPAIRS
1. Landing Gear System Repairs (3). Install new abrasion strip. Torque bolts
(1). Repair scratches and nicks by smooth- Nm) plus drag torque.
ing sharp edges.
(4). After installation, seal around bolts and
(2). Repair elongated, enlarged or worn all of parting edges of abrasion strip
holes in strut, either inboard or out- next to skid tube with an approximate
board. 0.060 inch (1.524 mm) bead (fillet) of
sealing compound (CM426) to make
(3). Repair bolt holes at large end of brace watertight.
that attaches to strut.
3. Ground Handling Bolt Replacement
(4). Replace strut; if cracked, if dents in
strut exceed 0.060 inch (1.524 mm) (Ref. Figure 401)
depth or if scratched and repaired area
depth would exceed 0.010 inch (0.254 (1). Remove nut, washers and spacer from
mm) when measured to surrounding skid tube.
unrepaired surface.
(2). Slide bolt with washers and spacer from
(5). Replace defective or badly damaged skid tube.
fairing.
(3). Install, in order, bolt, washer, new
(6). Replace cracked, dented or distorted spacer and washer through skid tube
braces. from outsidetoinside.
(7). Repair or replace damaged skid tube. (4). Install, in order, washer, spacer, washer
and nut onto bolt. Torque nut to 10 20
(8). Replace center beamtolanding gear inchpounds (1.13 2.26 Nm) plus
attachment bearings that exceed 0.040 drag torque.
inch (1.016 mm) axial play.
4. Safety Walk Tape Replacement
(9). Repair loose or defective pins and nuts
securing foot to bearing; replace (Ref. Figure 401)
defective bearing.
2. Abrasion Strip Replacement
(Ref. Figure 401) Item Nomenclature
CM724 Tape, nonslip
Item Nomenclature (1). Carefully pull or scrape away damaged
CM426 Sealing compound tape.
(2). Remove all residual adhesive from step

(1). Remove bolts securing defective by wiping with a clean cloth wetted by
abrasion strip(s) to skid. naphtha (CM220).
(2). Remove bolts securing abrasion strip to (3). Install new tape (CM724) and press
skid extension. Completely remove any firmly into place. Expel air bubbles
residual sealant. while pressing down tape.
Page 801
321060 Revision 19
MAINTENANCE MANUAL
5. Landing Gear Fairing Repair (3). Replace damaged guide/pin assembly or

guide half if guide is cracked, pins are
(Ref. Figure 402) bent or badly worn.
(4). Replace springs that are badly worn or

Consumable Materials rusty, or if free length is less than 8.72
(Ref. Section 910000) inches (22.149 cm).
Item Nomenclature
CM412 Adhesive, bonding, vulcanized (5). Replace fillet if teflon strip is loose or
badly worn.
(1). Replace an excessively damaged lower (6). Replace damaged strut bracket.
fairing. Remove rivets, locate new part and
install blind rivets. Use next larger size
(2). Replace damaged fairing bracket or rivets if mating holes in strut are
lower guide. Remove rivets, locate new enlarged.
part and install blind rivets. Use next
larger size rivets if mating holes in (7). Replace unserviceable rubber seals; use
strut are enlarged. adhesive (CM412).

Skid tube (2) 0.200 / 5.08 0.010 / 0.254, from aft side of (Same as for No cracks 0.250 / 6.350
(1) aft strut to 10 inches (25.4 cm). nicks) (1) allowed (1) (3)
forward of the strut, with
cleanup not exceeding 0.015 /
0.381; 0.015 / 0.381 if forward
of that point to start of curved
section, with cleanup not
exceeding 0.020 / 0.508 (1)
Forward foot 0.060 / 1.524 0.060 / 1.524 0.010 / 0.254 No cracks No holes
allowed allowed
Strut 0.060 / 1.524 (1) (1) No cracks No holes

allowed allowed
Brace 0.050 / 1.270 0.010 / 0.254 0.005 / 0.127 No cracks No holes

allowed allowed
Damper assembly 0.060 / 1.524 0.010 / 0.254 0.010 / 0.254 No cracks No holes
(5) allowed allowed
Fittings 0.010 / 0.254 0.010 / 0.254 0.010 / 0.254 No cracks No holes

allowed allowed
Aft foot 0.060 / 1.524 0.060 / 1.524 0.010 / 0.254 No cracks No holes
allowed allowed
Foot bearing 0.010 / 0.254 0.010 / 0.254 0.010 / 0.254 No cracks No Holes
allowed allowed
Page 802
Revision 19 321060
MAINTENANCE MANUAL

Skid extension 0.010 / 0.254 0.010 / 0.254 (4) 0.010 / 0.254 No cracks No holes
(4) (4) allowed allowed
NOTES:
(1) For other repair data, refer to CSPSRM6.
(2) Repair of minor skid tube damage on forward (curved) section is not required, but surface finish must be
restored.
(3) Hole must be plugged with correct size blind rivet.
(4) No damage is allowed on skid extension where skid and sleeve are attached.
(5) No dents allowed in damper barrel.

321060 Revision 19
MAINTENANCE MANUAL
Section
324000
Ground Handling
Wheels
(369D/E/FF 500N)
MAINTENANCE MANUAL

1. Ground Handling Wheel Assembly (2). With ground handling wheels in the
retracted position, align and engage the
The standard ground handling wheel assem- skid fittings.
blies provide a means of moving the helicopter
by hand or by towing. NOTE: Slide wheel assembly for and aft to en-
sure locking mechanism is securely locked
The special ground handling wheel assemblies into place.
for use with helicopters equipped with
emergency or utility floats provide a means of (3). Install jack handle over the wheel
moving the helicopter by hand only. assembly socket, install lock pin and
rotate handle downward to lower the
A. Ground Handling Wheel Description and
wheels and raise the helicopter.
Operation
(1). Standard ground handling wheel Hold downward pressure on
WARNING jack handle until the extend
assembly consists of one detachable
jack handle and two twowheeled lock snaps into locked position. If the
jacking assemblies that can be lock is not properly engaged and the
straddlemounted to the left and right handle is released, the upward swing of
landing gear skids by use of existing the handle could cause serious person-
ground handling wheel fittings. The al injury.
wheels are manually lowered with a
detachable jack handle and are held in (4). Check that the extend lock is engaged;
the down position (helicopter raised on then release downward pressure and
wheels) by a mechanical lock. The remove jack handle.
jacking assemblies are equipped with
two tow bar attach fittings for towing. (5). Install second ground handling wheel
assembly on the other skid in the same
(2). Special ground handling wheels are manner.
needed in place of standard ground
handling wheel assemblies for moving a 3. Special Ground Handling Wheel
helicopter equipped with emergency or Installation and Use
utility floats. These wheel assemblies
are specially designed for use with (Ref. Figure 201)
emergency floats and raise the landing
skids higher off the ground than Damage may result from push-
standard ground handling wheels. A
CAUTION ing up and/or pulling down on
channel provides support for the the tail boom to facilitate installation of spe-
underside of the landing gear skid. A cial ground handling wheels.
rubber pad on the channel furnishes
sufficient skid retaining friction NOTE: When the helicopter is jacked from one
without need for attachment of wheel side only, a cushion saddletype support
assembly to skid. Guards above the should be placed under the tail boom at the
wheel on each side of the channel jacking pad location for extra stability.
prevent wheel chafing of floats.
(1). Install and use special ground handling
2. Standard Ground Handling Wheel wheel assemblies as follows.
Installation and Use
(a). Jack up one side of the helicopter for
(1). Position ground handling wheel clearance to place ground handling
assembly over the skid tube at the wheel assembly under the landing
location of the skid fittings. gear skid.
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324000 Revision 19
MAINTENANCE MANUAL
WHEEL ASSEMBLY
HANDLE
G324001
Figure 201. Ground Handling Wheel Assembly (Standard)

(b). Position ground handling wheel (6). To remove axle shaft from housing,
assembly below the ground handling remove roll pin and slide shaft from
fittings, which is the approximate housing.
center of gravity (CG) point.
5. Standard Ground Handling Wheel
4. Standard Ground Handling Wheel Reassembly (Early Configuration)
Disassembly (Early Configuration) (1). If previously removed, install axle shaft
into housing and secure with roll pin.
(1). Remove cotter pin and washer from
axle shaft and slide hubandwheel (2). Using suitable bearing press, install
assembly off axle. bearings in hub.
(2). Remove three nuts securing wheel to (3). Install washer, hub assembly and
hub. washer on axle. Shim hub assembly,
0.010 inch maximum, using AB257824
Severe personal injury or washers, as required, between bearing
WARNING damage to property can oc- and outer washer and install cotter pin.
cur if tire is not deflated before at-
tempting to separate wheel halves. (4). Using talcum powder, insert tube into
tire and install on wheel halves.
(3). Deflate tire and remove six nuts, (5). Secure wheel halves together using six
washers and screws securing wheel screws, washers and nuts.
halves.
(6). Inflate tire in accordance with man-
(4). Remove tire and tube from wheel. ufacturers specifications.
(5). Using suitable bearing press, remove (7). Install wheel on hub assembly using
bearings from hub. three nuts and washers.
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Revision 19 324000
MAINTENANCE MANUAL
ROLL
LOCK PIVOT PIN
BUSHING PIN
SPRING
RETAINER LOCK PIN
ROLL PIN
HANDLE
INNER
WHEEL
TIRE
BUSHING
TUBE
BASE
OUTER WHEEL ROLL
PIN HUB
RACE
BEARING
WASHER
NUT
DUST CAP
COTTER PIN
ROLL PIN
AXLE
SEAL
BEARING
RACE
G324003
Figure 202. Ground Handling Wheel Assembly/Disassembly
Page 203
324000 Revision 19
MAINTENANCE MANUAL
6. Standard Ground Handling Wheel (7). Secure wheel halves together using six
Disassembly (Current Configuration) screws, washers and nuts.
(Ref. Figure 202) (8). Inflate tire in accordance with man-

ufacturers specifications.
(1). Remove three nuts and washers
securing wheel and tire assembly to (9). Install wheel on hub assembly using
hub and axle assembly. three nuts and washers.
(2). Remove dust cap, cotter pin, nut and 8. Standard Ground Handling Wheel
washers from hub and axle assembly. Servicing
At regular intervals, Ground Handling Wheel
Severe personal injury or Assemblies should be maintained to provide
WARNING damage to property can oc-
safe use and longer life of components.
cur if tire is not deflated before at-
tempting to separate wheel halves. (1). Ensure tire pressure is within manufac-
turers specifications.
(3). Deflate tire and remove six nuts,
washers and screws securing wheel (2). Grease bearing using MILG81322,
halves. Mobil Grease 28 or alternate grease
MILG25537, Aero Shell using
(4). Remove tire and tube from wheel. available grease zerk (primary method)
or hand pack (alternate method).
Do not remove spacer from hub
CAUTION body. Spacer is a close tolerance (3). Remove excess play of hubtoaxle by
press fit and should not be removed. inserting AB257824 washers, as
required, between bearing and outer
(5). Remove seal, bearings and races from washer to maintain 0.010inch axial
hub body. play.
(6). To remove axle shaft from housing, 9. Special Ground Handling Wheel
remove roll pin and slide shaft from Disassembly
housing.
(Ref. Figure 204)
7. Standard Ground Handling Wheel (1). Remove cotter pin, nut and washer and
Reassembly (Current Configuration) remove wheel assembly.
(Ref. Figure 202) (2). To remove axle shaft, remove slotted
pin and slide shaft from housing.
(1). If previously removed, install axle into
housing and secure with roll pin. (3). Using suitable bearing press, remove
bearings from hub.
(2). Install races, bearings and seal in hub.
10. Special Ground Handling Wheel
(3). Install hub assembly on axle shaft and Reassembly
secure with washer and nut.
(Ref. Figure 204)
(4). Tighten nut until there is a maximum (1). Insert axle shaft into housing and
of 0.010 inch axial play. Remove excess insert slotted pin.
axial play by inserting AB257824
washers, as required, between bearing (2). Using suitable bearing press, install
and outer washer. bearings into hub.
(5). Install cotter pin and dust cap. (3). Install wheel on axle using washer, nut
and cotter pin. Adjust axial play, 0.010
(6). Using talcum powder, insert tube into inch maximum, using AN960C1016
tire and install on wheel halves. washers as required.
Page 204
Revision 19 324000
MAINTENANCE MANUAL
11. Special Ground Handling Wheel Servicing solid rubber tires and therefore require no
(Ref. Figure 204) The special ground handling servicing.
wheel assemblies have sealed bearings and
SKID TUBE
RUBBER PAD
(NOTE 1)
SKID FITTING
(REF) (NOTE 2)
GUARD
FAIRING WELD SUPPORT
STRUT
EMERGENCY FLOAT
CONTAINMENT COVER
SHAFT RUBBER TREAD WHEEL
NOTES:
1. LANDING GEAR SKID TUBE UNDERSIDE RESTS ON
CAUTION: BE SURE THAT FLOAT CONTAINMENT
RUBBER PAD AND IS SUPPORTED BY WELD SUPPORT
COVER CLEARS AND IS NOT PINCHED BY
WITHOUT RESTAINING ATTACHMENT.
HANDLING WHEEL ASSEMBLY.
2. NOT USED WITH GROUND HANDLING WHEELS SHOWN.
3. MAXIMUM LOAD RATE 800 LBS. (363 KG) AT 8 RPM.
G324000A
Figure 203. Special Ground Handling Wheel Assembly (Float Type)
Page 205
324000 Revision 19
MAINTENANCE MANUAL
PAD
WELD ASSEMBLY
WHEEL
COTTER PIN
WASHER
SLOTTED PIN
SHAFT NUT
WHEEL
G324002
Figure 204. Special Ground Handling Wheel Assembly/Disassembly
Page 206
Revision 19 324000
MAINTENANCE MANUAL
Section
324060
Ground Handling
Wheels (600N)
MAINTENANCE MANUAL

1. Ground Handling Wheel Assembly The jack retains a vertical position
during raising and lowering of the
The standard ground handling wheel assem- wheels.
blies provide a means of moving the helicopter
by hand or by towing. The ram of the jack is in constant
contact with the upper cross frame of
A. Ground Handling Wheel Assembly the main body, providing vertical
Description and Operation pumping leverage forcing the wheels
down.
The ground handling wheel set consists of two (4). Attach Cradle and Main Frame Body:
dual wheel assemblies, which are designed to
support a fully equipped helicopter. The wheel The attach cradle is attached to the
assembly consists of two pneumatic tires, rims, main frame body by means of two pins
spindles, hydraulic jack and attach cradle. with cotter pins. The contoured cradle
is slotted to lock onto the skids.
(1). Tires:
2. Ground Handling Wheel Assembly
The tires are 10 ply with a maximum Maintenance
rating of 1120 lb at 65 psi (508 kg at (1). Ensure tire pressure is within manufac-
448 kPa). turers specifications.
(2). Rims: (2). Inspect tires for wear and cuts, none
allowed.
The rim rotates on a spindle by means
of inner and outer tapered roller (3). Inspect wheels for cracks and defects,
bearings with an external grease fitting none allowed.
on the hub for periodic servicing. (4). At regular intervals, repack wheel
bearings and grease spindle assembly
(3). Hydraulic Jacks: guides.
A six ton jack is held in place on the (5). At regular intervals, inspect hydraulic
main frame by a support plate. jacks for proper fluid levels.
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324060 Revision 19
MAINTENANCE MANUAL
NOTE
FRAME ASSEMBLY
JACK
GUIDE
NUT
SPINDLE ASSEMBLY
SEAL
HANDLE ASSEMBLY WHEEL BEARING
TIRE
GUIDE
WHEEL BEARING
CLEVIS
HUB CAP
COTTER PIN
SPINDLE
CARRIER WASHER
NOTE:
PERIODICALLY GREASE SPINDLETOGUIDE
INTERFACE FOR PROPER OPERATION. 6G32042
Figure 201. Ground Handling Wheel Assembly
Page 202
Revision 19 324060
MAINTENANCE MANUAL
Section
328100
Utility Float System
(369D/E)
MAINTENANCE MANUAL
UTILITY FLOAT SYSTEM

1. Utility Float Description and Operation 0.5 psig (3.447 kPa) for each compart-
ment.
Utility floats consists of neoprene airtight
chambers separated by internal walls that (3). Place BATTERYOFFEXT PWR
provide six individual watertight compart- switch at BATTERY. Actuate POS LT
ments. Skid attachment strips (girts), bonded switch to the ON position. Observe that
to underside of floats, are bolted to landing left and right position lights illuminate.
gear skids and extensions. Floats are inflated Place all switches at OFF position.
to a normal operating pressure of 2.0 psig (14
kPa). Relief valves release air pressure if 2. Utility Float Inspection
compartment pressure becomes excessive. A (1). Inspect float chambers for correct air
stabilizer assembly is attached at the aft end pressure.
of the skid tube extension.
(2). Inspect float bags for abrasion and
NOTE: If a helicopter with utility floats is tilted chafing.
back on the tail skid to install ground handl-
ing wheels, approximately 1 pint (0.437 li- (3). Inspect pressure relief and fill valves
ter) of oil is trapped in the tail rotor trans- for condition and closure.
mission. This condition gives a false sight A. Skid Tube and Extension Assembly
plug oil level indication immediately after Inspection
return to a level attitude. After ground ru-
nup, oil level indication is normal. Inspection of skid tube and extension assembly
is identical to that described in Sec. 321000.
A. Utility Float Operational Check
B. Utility Float Repair
With helicopter on the ground and utility Repair materials and information are avail-
floats inflated to normal operating pressure, able from the float manufacturer. Make
perform the following operational checks: repairs to utility floats using materials
according to manufacturers instructions.
(1). Check all float compartments for 2.0
psig (14 kPa). 3. Utility Float Troubleshooting
NOTE: Changes in atmospheric pressure, and Refer to Table 201 for troubleshooting informa-
temperature of float compartments affects tion. Troubles presented are listed in order of
pressure gage readings. A temperature possible occurrence during performance of
change of 1 degree equals 0.032 psig (0.2206 operational check. This information is pro-
kPa). vided to aid in isolating faults found during
operational check or normal operation of the
(2). Check for pressure drop with pressure system. The fault is then removed by repair or
gage that indicates 0 15 psi (0 103 replacement to return the system to trouble
kPa), graduated in 0.5 psi (3.447 kPa) free operation. Troubleshooting and repair of
increments. Maximum allowable internal components of the float is beyond the
pressure drop in 24 hours is limited to scope of this section.
Page 201
328100 Revision 19
MAINTENANCE MANUAL
Table 201. Troubleshooting Utility Floats

Low air pressure Damaged float Repair float.
Defective fill valve Replace fill valve.
Defective pressure relief valve Replace pressure relief valve.
Position lights do not POS LT switch not at ON position Actuate switch to ON position.
illuminate
Position light lamp defective Replace lamp.

Defective electrical wire splice Repair electrical splice.
4. Utility Float Replacement B. Utility Float Installation
(Ref. Figure 201) Consumable Materials

A. Utility Float Removal Item Nomenclature
Prior to removal of utility floats, jack or hoist
CM318 Primer
helicopter until landing gear dampers are fully
extended and landing gear skid tubes are at CM425 Sealing compound
least six inches (15cm) from ground. Skid and CM717 Tape, pressure sensitive
fairing assemblies must be removed to remove
float assemblies Ref. Sec. 321000). NOTE: Prior to assembly, apply primer
(CM318) to all mating surfaces.
Maintain helicopter in level at-
CAUTION titude during jacking or hoist- (1). On early configuration extended
ing. Do not raise one side of helicopter at a landing gear, coat abrasion strip with
time. zinc chromate putty (CM209) and
install using screws.
(1). Remove position light cover screws, (2). Install bolt covers using existing screws
then remove cover. Remove position and wrap with two overlapping layers
light mounting screws and position of tape (CM717).
light. Retain electrical wire for installa-
tion. (3). Install tyrap bracket on forward struts.
(4). Align extension and bearing sleeve
(2). Remove bolts and washers attaching
holes; install rivets using wet primer
stabilizer assembly to aft section of
(CM318).
floats.
(5). On early configuration extended
(3). Open fill valve at each of six float landing gear, install skid tube extension
chambers. A suction device such as a as follows:
vacuum cleaner speeds air evacuation.
(a). Install indexing plug in float kit
extension tube.
(4). Remove bolts, washers, gravel guards
and abrasion strip attaching float to (b). Align indexing plug tabs with slots in
skid assembly and skid extension. foot bearing sleeve on helicopter;
install indexing plug and forward end
(5). Depress float around strut assemblies of extension tube over bearing sleeve.
and pull float free from skid tube Use care not to damage packing
assembly and skid extension. during installation.
Page 202
Revision 19 328100
MAINTENANCE MANUAL
(c). Align bolt holes in bearing sleeve, bolts to 25 35 inchpounds (2.82

indexing plug and extension tube; 3.95 Nm).
install rivets with wet primer.
(9). Connect wiring to position light then
(d). Coat mating surfaces of abrasion install position light with screws.
strip with zinc chromate putty. Install cover and secure with screws.
(e). Install abrasion strip on extension 5. Skid Tube Extension Replacement
tube with rivets and wet primer.
(Ref. Figure 901)
(f). Seal all edges of abrasion strip with
approximately 0.060 (1.524 mm) bead A. Skid Tube Extension Removal
of sealing compound (CM425). (1). Remove bolts and washers; then
remove stabilizer support from aft end
(6). Position floats on skid and extension
of skid extension.
assembly. Align bolt holes in float girt
and skid assembly. Secure floats in (2). Remove bolts and nuts attaching
place using gravel guards, abrasion extension to skid tube assembly.
strips, bolts and washers. Coat bolts
and washers with primer and torque to (3). Separate skid extension from skid tube.
25 35 inchpounds (2.82 3.95
B. Skid Tube Extension Installation
Nm).
(1). Insert skid extension into aft section of
(7). Position stabilizer cap on skid tube skid tube.
extension. Coat mating surfaces with
sealing compound and secure with bolts (2). Align bolt holes and secure in place
and washers. using bolts and nuts as applicable.
(8). Position stabilizer assembly on aft (3). Position stabilizer support on aft end of
section of skid extension and secure in skid extension and secure in place
place using bolts and washers. Torque using bolts and washers.
Page 203
328100 Revision 19
MAINTENANCE MANUAL
G328012
Figure 201. Utility Float Installation
Page 204
Revision 19 328100
MAINTENANCE MANUAL
UTILITY FLOAT SYSTEM

1. Utility Float Initial Installation (6). Remove cargo compartment and aft
landing gear steps.
The utility float kit may not be installed in
combination with the following: NOTE: Passenger steps, 369D26505 and
Passenger steps 369D292028, may not be installed in combi-
Hoist kit nation with utility floats. Upon removal of
Litter kit 369D292028 step assembly, install
Fourbladed tail rotor PLT210103 bolts (2 per assembly) coated
with sealing compound (CM425) into holes
A. Preparation for Installation where step attaching hardware was located.
Consumable Materials (7). Remove hardware that secures trailing

(Ref. Section 910000) edge of lower fairings to strut assem-
Item Nomenclature blies. Carefully spread trailing edge of
lower fairings and remove fairings.
NOTE: If preload condition prevents removal of
Instructions in the following paragraphs are skid assemblies, disconnect one brace as-
applicable to both left and right landing gear sembly from skid assemblies to eliminate
assemblies. Preparation for installation of preload (Ref. Sec. 321000).
utility floats includes the following:
(8). Remove ABC bolts from forward and aft
NOTE: Make sure that the BATTOFFEXT strut assemblies (Ref. Sec. 321000).
switch is set to OFF. Retain ABC hardware for reuse.
Remove skid assemblies with foot
(1). Check all cockpit electrical switches in assemblies attached.
the OFF position.
B. Disassembly of Extended Landing Gear
(2). Identify all components, including
attaching hardware, or components (Ref. Figure 901) Complete disassembly of
removed for access to work areas. landing gear is not required; however, certain
Protect components from damage and items must be removed.
foreign matter until installed.
(3). Using jacking or hoisting methods, Consumable Materials

raise helicopter 6 inches (15 cm) clear of (Ref. Section 910000)
ground. Item Nomenclature
(4). Remove landing gear (Ref. Sec. CM318 Primer

321000). Removal of landing gear is
identical to that described in Sec.
321000, except that removal of (1). Remove screws from float attach
complete landing gear is not required. fittings.
Remove extended landing gear accord-
ing to Sec. 321000, except as follows: (2). Remove bolts and abrasion strip from
skid extension.
(5). Remove screws attaching position light
assemblies to skid assemblies. Retain (3). Remove bolts attaching skid tube
screws for reuse. Disconnect electrical extension.
harness and remove position light
assemblies. (4). Remove skid tube extension.
Page 901
328100 Revision 19
MAINTENANCE MANUAL
G328008
Figure 901. Extended Landing Gear Disassembly
Page 902
Revision 19 328100
MAINTENANCE MANUAL
NOTE: When installing the 369D29280817 D. Landing Gear Skid Extension Assembly
and 18 extension tubes, it will be necessary
to remove and replace the 369D26012 or the (Ref. Figure 903)
369D260125 sleeve adapter with a new 5
(undrilled at aft end) sleeve adapter (Ref. Consumable Materials
Sec. 321000). (Ref. Section 910000)
Item Nomenclature
(5). Remove bolts attaching abrasion strip CM209 Zinc chromate putty
to skid tube. Do not remove abrasion CM318 Primer
strips. Retain four bolts for reuse. CM425 Sealing compound
(6). Remove fairing attach brackets from

foot assemblies. Coat screws and (1). On all types of landing gear skid tube
washers with primer (CM318) and extensions:
reinstall screws and washers. (a). Coat mating surfaces of the correct
plug with zinc chromate putty
C. Landing Gear Strut Modification (CM209); assemble plug to tube with
rivets coated with primer (CM318).
(Ref. Figure 902) For modification of landing Seal edges with sealing compound
gear strut assemblies to accommodate installa- (CM425).
tion of utility floats and return to extended
landing gear configuration when utility floats (b). Coat mating surface of support
are removed, perform the following: assembly and tube with zinc chro-
mate putty; install using bolts and
washers.
(Ref. Section 910000) (2). Assembly of landing gear skid exten-
Item Nomenclature sion (369D29280817 and 18) on
current configuration landing gear:
CM318 Primer
NOTE: The 369D29280817 and 18 skid tube
extension assemblies may only be installed
on extended skid gear having new (un-
drilled) 369D260125 adapter, sleeveskid
(1). Using drill motor and number 15 drill
installed. For replacing the 369D26012 ba-
bit, drill two holes through lower
sic sleeve with the 5 sleeve (Ref. Sec.
fairing attach brackets and aft wall of
321000).
landing gear strut assemblies (view A).
Enlarge holes to 0.250 inch (6.350 mm) (a). Insert skid tube extension on to 5
diameter using 1/4 inch (6.35 mm) drill adapter sleeve. Align skid tube
bit. rivnut centerline with extension tube
rivnut centerline. Secure both
(2). Using number 30 drill bit, drill out assemblies with a suitable fixture.
huckbolts attaching bracket to strut.
Remove bracket. Seal huckbolt attach (b). Mark and match drill eight 0.1945
holes in strut with sealing compound 0.1965 inch (4.9403 4.9911 mm)
(CM425). Coat bare metal with primer diameter holes through tube and
(CM318). sleeve (use locations and dimensions
as stated in Figure 903); separate
skid tube extension from adapter
(3). Remove rivets attaching nutplates
sleeve.
(view B).
(c). Countersink holes, 100 x 0.378
NOTE: When floats are removed from landing 0.385 inch (100 x 9.6012 9.779
gear assembly, modified foot assembly mm) diameter in skid tube extension,
brackets may be reinstalled by using screws deburr and apply primer to bare
and washers. metal surfaces.
Page 903
328100 Revision 19
MAINTENANCE MANUAL
STRUT
CL
BRACKET C
L
SILASTIC
2 50
STRUT ASSEMBLY (TYPI-

CAL)
REMOVE NUT PLATE

LOWER FAIRING AT-
TACH BRACKET 0.59
KNIFE SPLICE
SEALANT
2.41
1.28 1.13
TYRAP BRACKET 0.250 DIAMETER 2
HOLES
BRACKET C
L
STRUT MODIFICATION
FORWARD FOOT MODIFICATION
G328009
Figure 902. Extended Landing Gear Modification
Page 904
Revision 19 328100
MAINTENANCE MANUAL
5.98 INCH 3.92 INCH 369D260125 SLEEVE

(15.189 CM) 0.40 INCH (9.957 CM) (REF)
(10.16 MM) NOTE 1
SUPPORT ASSEMBLY
(NOTES 3 & 4)
2.90 INCH
(7.37 CM) BOLT
(NOTE 2)
RIVNUT
(NOTE 2)
COMPONENT OF 369D29280817 AND 18

(FOR UTILITY FLOATS ONLY)
VISULOK
(8 PLS) (NOTE 2) RIVET
(NOTE 2)
PLUG
(NOTES 3 & 4)
EXTENSION TUBE
(NOTES 3 & 5)
(NOTES 3 & 5)
369D260125
ADAPTER SLEEVE
ABRASION STRIP
(NOTES 3 & 4)
VISULOK
(8 PLS) (NOTE 2)
BOLT
(NOTE 2)
NOTES:
1. MATCHDRILL 8 0.1945/0.1965 INCH (4.9403/4.9911 MM) DIAMETER HOLES THRU
BOTH TUBES AND CSK, 1005 X 0.378/0.385 INCH (9.6012/9.779 MM) DIAMETER.
APPLY PRIMER TO BARE METAL SURFACES.
2. COAT ATTACHING HARDWARE WITH PRIMER.
3. COAT MATING SURFACES WITH ZINC CHROMATE PUTTY.
4. SEAL MATING EDGES WITH SEALING COMPOUND.
5. SEAL MATING EDGES WITH SEALING COMPOUND.
G328010
Figure 903. Skid Tube Extension Installation
Page 905
328100 Revision 19
MAINTENANCE MANUAL
(d). Reinstall skid tube extensions on to E. Utility Float to Landing Gear Assembly
5 adapter sleeve using a thin coat of
sealing compound on mating sur- (Ref. Figure 904) The Utility Float Kit is shipped
faces. Seal with sealing compound. with as many parts assembled as practical;
Secure with eight visulok fasteners however, certain items require assembly at
coated with primer. installation.
(e). Install abrasion strip to each exten- Consumable Materials

sion tube with bolts and washers. (Ref. Section 910000)
Coat attaching hardware with Item Nomenclature
primer. Coat mating surfaces with CM209 Zinc chromate putty
zinc chromate putty and seal mating CM318 Primer
edges with approximately 0.060 inch
(1.524 mm) bead of sealing compound
to insure watertight fit. CM717 Tape, pressure sensitive
(3). Assembly of landing gear skid exten- NOTE: Prior to installation, apply primer
sion On current configuration ex- (CM318) to all attaching hardware.
tended landing gear:
(1). On early configuration extended
(a). Insert float kit extension tube over landing gear, coat abrasion strip with
adapter sleeve. zinc chromate putty (CM209) and
install with screws (view D).
(b). Align extension tube and sleeve (2). Install bolt cover pads using existing
holes, attach tube to skid with bolt screws and wrap with two overlapping
spacer and nut. layers of tape (CM717) (view B).
(4). Assembly of landing gear skid exten- (3). Coat mating surfaces of cap with
sion On early configuration extended sealing compound (CM425) and install
landing gear: using position light attaching screws.
(4). Temporarily install tyrap bracket with
(a). Seal all edges of skid plug with screw (view E).
sealing compound; install in tube by
using using rivets. (5). Position utility floats over landing gear
skids.
(b). Coat all surfaces of indexing plug and (6). Align bolt holes in floats with bolt holes
sleeve with sealing compound. in skid assembly. Position gravel
guards, coat bolts and washers with
(c). Insert sleeve adapter in tube and primer (CM318); attach floats, gravel
install using rivets. guards and abrasion strip using bolts
and washers. Torque bolts to 25 35
(d). Install packing and indexing plug in inchpounds (2.82 3.95 Nm).
tube; align holes in sleeve, plug
(7). Position cap assembly (view C) on skid
assembly and tube with skid assem-
tube extension. Coat mating surfaces
bly. Install rivets and bolts with
with sealing compound and secure with
primer (4).
bolts and washers.
(e). Coat mating surfaces of abrasion (8). Assemble structure assembly and
strip with zinc chromate putty (71). support assembly (view C). Coat mating
Install abrasion strips with screws surfaces with sealing compound and
and primer (4). Seal all edges with secure with bolts, washers, nuts and
approximately 0.06 in. bead of plate. Secure assembled stabilizer
sealant (3). assembly using bolts and washers.
Page 906
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MAINTENANCE MANUAL
F. Utility Floats/Landing Gear Installation If a preload condition prevents alignment,

disconnect one brace from strut assembly to
(Ref. Figure 902 and Figure 904) eliminate preload (Ref. Sec. 321000).
(4). Secure new wire to forward foot using
Consumable Materials tyrap bracket and screw (view E). Route
(Ref. Section 910000) wire to position light location through
Item Nomenclature tunnel provided in float. Use tie strap
CM318 Primer as required. Attach wire to position
light.
CM430 Sealant, solvent resistant (5). Install bracket using screws. Secure tab
CM717 Tape, pressure sensitive and position light to bracket using
screws, washers and nuts. Install cover
using screws (view A).
(1). At forward strut, install approximately
3 feet (92 cm) of wire to position light (6). Install bolt cover pads using tape
electrical harness using splice and (CM717) (view B).
silicone tube. Apply sealant (CM430) to
(7). Locate strobe light (Ref. Figure 901
ends of splice. Route wire through
view A). Remove attaching hardware
nutplate hole in forward foot (Ref.
and disconnect wire harness. Remove
Figure 902, view A) and seal gaps and
strobe light and doubler. Retain
holes with sealing compound (CM425).
attaching hardware and strobe light.
(2). Connect wire harness to position light (8). Position shield and strobe light (Ref.
using bracket, screw, washer and nut Figure 904). Connect wire harness to
(Ref. Figure 904, view A). Secure wire strobe light and install shield and
harness to bracket with strap. Seal strobe light using hardware retained
connection with sealant (CM430). from removal.
(3). Apply sealing compound (CM425) to (9). Install landing gear fairings (Ref. Sec.
mating surfaces of foot and strut 321000).
assemblies. Insert forward and aft foot
assemblies into strut assemblies. Align G. Weight and Balance
bolt holes, apply thin coat of primer Weight and balance changes that result from in-
(CM318) to ABC bolts and install bolts stallation of utility floats are listed in Table 901.
while primer is still wet. Torque bolts to After installation of utility floats, incorporate
40 60 inchpounds (4.52 6.78 changes to helicopter weight and balance record
Nm). as instructed in Section 081000.

Weight Arm Moment
Configuration lbs (kg) in. (cm) in.lb/100 (kg mm/100)
369D290086Basic
Added +131.8 (59.783) 122.2 (310.39) +161.06 (1855.60)
Removed 9.5 (4.309) 103.9 (263.91) 9.87 (113.71)
Change +122.3 (55.474) 123.6 (313.94) +151.19 (1741.89)
369D290086501
Added +143.1 (64.909) 125.5 (318.77) +179.59 (2069.09)
Removed 8.1 (3.674) 99.8 253.49) 8.08 (93.09)
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MAINTENANCE MANUAL

Configuration lbs (kg) in. (cm) in.lb/100 (kg mm/100)
Change +135.0 (61.235) 127.0 (322.58) +171.51 (1976.00)
369D290086503
Same as 501 except delete: 143.1 (64.909) 125.5 (318.77) 179.59 (2069.09)
369D2920353 71.5 (32.432) 125.5 (318.77) 8.97 (103.35)
369D2920354 71.5 (32.432) 125.5 (318.77) 8.97 (103.35)
and install:
369D2920355 +25.7 (11.657) 162.0 (411.48) +4.16 (47.93)
369D2920356 +25.7 (11.657) 162.0 (411.48) +4.16 (47.93)
Change +51.5 (23.360) 161.9 (411.23) +8.33 (95.97)
Page 908
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MAINTENANCE MANUAL
G3280111
Figure 904. Utility Float Buildup (Sheet 1 of 2)
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328100 Revision 19
MAINTENANCE MANUAL
G3280112
Figure 905. Utility Float Buildup (Sheet 2 of 2)
Page 910
Revision 19 328100
MAINTENANCE MANUAL
Section
328200
Emergency Float
System
(369D/E/FF 500N)
MAINTENANCE MANUAL
EMERGENCY FLOAT SYSTEM

1. Emergency Float System Description and (2). Flotation Equipment Emergency
Operation flotation equipment consist of two
inflatable emergency floats, electroni-
A collapsed emergency float with an emergen- cally controlled inflation equipment,
cy inflation system (stowed condition) is four landing gear fairings and landing
attached to each landing gear skid. The floats gear skid tube extensions. Nutplates on
may be fully inflated during flight in approxi- each skid tube and extension provide
mately five seconds. The electrically controlled for float attachment. A cabin entry step
inflation system includes a selftest capability may be used with the landing gear
to provide the pilot with a visual indication of without interference with the floats.
the electrical circuit reliability. Landing on
water or land is permitted when emergency (3). Inflatable Emergency Floats Each of
floats are inflated. the two inflatable neoprene emergency
floats consists of sealed airtight
Emergency flotation equipment in the stowed chambers separated by internal walls
condition does not restrict normal land that provide five individual watertight
operation of the helicopter. When inflated, the compartments. Skid attachment strips
floats will support the helicopter on water at (girts), bonded to the underside of the
maximum gross weight. After emergency floats, are bolted to the landing gear
inflation, the inflation system may be serviced skids. In addition, fore and aft web
with fully charged dry air or nitrogen pressure support straps secure the floats to the
vessels, and the floats repackaged to a skids. The floats are inflated to a
streamlined stowed condition. nominal operating pressure of 4.0 psig
(28 kPa) by the emergency inflation
A. Emergency Float Description system upon pilot activation of the
inflation system electrical control
(1). Electrical System The emergency float equipment. Relief valves provide for air
electrical installation assumes prior pressure release at a compartment
incorporation of the 369H9012931, pressure of 4.5 psi (31 kPa) or above.
369H90129505 or 369H90129511
pilots cyclic stick grip kit. The emer- A snapon containment cover with
gency float electrical system includes a lacing restrains the float in the stowed
circuit breaker, visual indicator switch configuration until the emergency
for testing circuit operation reliability, inflation system inflates the float. The
and a relay. The pilots cyclic stick grip containment cover inboard side auto-
is equipped with an EMERG/FLOAT matically unsnaps and is pushed
pushbutton switch. When the pilots outboard as the float inflates. After
grip switch is actuated, the electrical emergency float use, deflation, pressure
system energizes and provides electrical vessel recharging and folding, the cover
power for simultaneous operation of the is again snapped in place over the float
left and right emergency float inflation and replaced for subsequent reuse.
system. The float inflation system
consists of an electrically operated A mooring ring atop each end of the
solenoid valve, or squib valve, attached float is furnished for towing and
to a compressed dry air or dry nitrogen mooring. An extended landing gear skid
pressure vessel. When the solenoid is tube extension supports the float aft
energized or the squib is actuated, the section on the landing gear. Forward
pressure vessel valve opens and and aft restraining straps are provided
releases compressed dry air or dry at landing gear strut and fairing
nitrogen into compartments of each locations. Gap covers close off the
float. inboard cutouts for the strut fairings.
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MAINTENANCE MANUAL
(4). Emergency Inflation System The (2). Check girt to skid attaching hardware
emergency inflation system consists of for condition and corrosion.
a charged compressed pressure vessel,
air hoses, valves and associated (3). Check float cover fasteners and lacing
components for inflation of the emer- for security.
gence floats. A complete emergency
inflation system is installed on and is (4). Examine float stowage cover for
part of each float. abrasive damage that may have
disturbed package float.
When actuated by inflation system (5). Perform an operational check of float
electrical control equipment, a solenoid inflation system electrical control
valve or squib valve attached to the equipment.
pressure vessel releases compressed dry
air or dry nitrogen for distribution
4. Emergency Float Inspection
through the air hoses and inlet check
valves for the five float compartments. NOTE: To be performed every six months or as
A relief valve on each float compart- necessary.
ment opens if compartment pressure
exceeds 5 0.5 psi (34.5 3.5 kPa). (1). Check for proper air pressure indication
on pressure gage.
The pressure vessel operating pressure
is 3000 3575 psig (20684 24649 kPa) (2). If float is stowed, unsnap containment
at 65 85F (18 30C); 3500 75 psig cover and loosen restraining lacing for
(24132 517 kPa) at 65 85F (18 access to emergency inflation system
30C) is preferred. The manifold is components.
attached to the pressure vessel along
with an indicating pressure gage, filler (3). Remove pressure vessel, inspect for
valve and a pressure relief valve. The damage and scratched, nicked or
pressure vessel relief valve operates at otherwise damaged paint coating.
and above 4250 250 psig (29303 1724
kPa). Detachable rubber boots cover the NOTE: Superficial paint coating damage
filler and pressure relief valves for should be repaired by paint touchup.
protection against chafing. The pres- (4). Inspect valves, air hoses and other air
sure vessel may be detached from the distribution components for damage,
float for servicing. deformity, strain, chafing or corrosion.
2. Certification and Shelf/Service Life NOTE: Corrosion of the electrically operated

solenoid/squib valve may occur as a result of
The Federal Aviation Administration (FAA) improper charging of the pressure vessel.
has granted Squib PN 50035271 of the Ensure that only dry air or dry nitrogen is
squibactuated emergency float valve a used to charge the pressure vessel.
provisional fiveyear life limit. This life limit
is established by date of manufacture, which is (5). Perform an inflation system electrical
inkstamped on the body of the squib (Ref. control equipment operational check to
Sec. 040000). ensure electrical continuity and
connection of solenoid/squib valve.
3. Emergency Float Inspection (Stowed Ensure that pressure vessel
Configuration) CAUTION gage is visible through inspec-
tion window.
NOTE: The following inspections must be per-
formed daily and before each flight. (6). Tighten and retie the lacing and snap
the containment cover in place if not
(1). Observe vessel pressure through continuing to Float Compartment
inspection window. Pressure Test.
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MAINTENANCE MANUAL
Table 201. Troubleshooting Emergency Flotation Equipment

A charged float pressure vessel must be discharged before the associated float valve is removed
CAUTION from the pressure vessel. Use care to prevent accidental float inflation.
No reliability light indication, Burnedout lamp. Replace lamp.
either left or right.
Defective connection or wiring. Repair connection or wiring.
Open circuit to solenoid float valve. Replace float valve.
No reliability light indication, Defective connection or wiring. Repair connection or wiring.

both left and right.
Reliability light indication for Defective actuating switch. Replace actuating switch.
both floats; neither float
inflates. Defective actuating switch wiring. Repair wiring.
Float leaks air. Damaged float. Repair float.
5. Emergency Float Compartment Pressure 6. Emergency Float Inspection (After

Test Inflation)
To be performed every 6 months or after 5

inflations (Ref. Sec. 040000).
(1). Inflate all float compartments at the fill Item Nomenclature
valves to 4.5 psi (31 kPa) for one hour. CM220 Naphtha aliphatic
Check for leaks and condition.
(2). Continue inflation to 5.5 psi (38 kPa) (1). Clean float as follows:
and check that chamber pressure relief (a). Clean away any oil or grease with
valves operate. naptha (CM220).
(3). Lower pressure in all five float com- (b). Wash down with soapy water; flush
partments to 2.0 psi (14 kPa) and let with clear fresh water and allow to
stand for 24 hours. air dry.
NOTE: Changes in atmospheric pressure and (c). Clean air pressure gage inspection
temperature during pressure test of float window with a clean cloth and fresh
compartments will affect pressure gage water.
readings. A temperature change of 1 degree (d). After inspection is complete, dust
equals 0.032 psig (0.2206 kPa). with talc.
(4). Check the pressure drop with a pres- (2). Recharge pressure vessel to 3500 psig
sure gage that indicates 0 15 psi (0 (24132 kPa) at 75F (24C).
103 kPa), graduated in 0.5 psi (5 kPa)
increments. The maximum allowable (3). Inspect float bags for abrasion and
pressure drop in 24 hours is limited to chafing.
0.5 psi (5 kPa) per compartment.
(4). Inspect pressure relief valves for
(5). If a pressure drop occurs, check floats condition and closure.
for soundness. (5). Inspect check valves for condition.
(6). Tighten and retie the lacing and snap (6). Inspect all hoses and connectors for
the containment cover in place. condition and security.
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MAINTENANCE MANUAL
(7). Check float girts, web support and NOTE: Changes in atmospheric pressure and
restraining straps for condition and temperature during pressure test of float
secure attachment to skid tube. compartments will affect pressure gage
readings. A temperature change of 1 degree
(8). Check all release snaps and fasteners equals 0.032 psig (0.2206 kPa).
for condition and serviceability.
(2). Check the pressure drop with a pres-
(9). Check that pressure vessel relief valve sure gage that indicates 0 15 psi (0
and filler valve boots are installed. 103 kPa), graduated in 0.5 psi (5 kPa)
increments. The maximum allowable
(10). Repack floats. pressure drop in 24 hours is limited to
0.5 psi (5 kPa) per compartment.
7. Emergency Float Test
(3). If a pressure drop occurs, check floats
The squib is an electrically for soundness.
WARNING fired explosive device. Keep
squibs away from all sources of heat, 9. Emergency Float Repair
open flame, sparks and electrical con- Contact MDHS Field Service Department for
tacts. Squib plugs are to be in place un- repair information.
til squibs are installed in aircraft.
10. SolenoidtoSquib Rework Procedure
(1). Perform inflation operational reliability The following is a procedure to replace the
test of float inflation electrical system solenoid, which is no longer manufactured, to
as follows: the squib valve.
(a). Press LH/FLT and RH/FLT combi- (1). Turn off electrical power.
nation presstotest switch located
(2). Unpack emergency floats.
below the lower switch and circuit
breaker panel on the sllmline instru- (3). Remove valve protector and unlace
ment panel and at the topcenter of cylinder sling lacing cords (Ref.
the "T" panel, to test float inflation Figure 402).
electrical circuit reliability. (4). Disconnect solenoid valve electrical
NOTE: Pressing the presstotest switch ap- wiring knife splice at (SP4, SP5, SP9
plies low voltage (insufficient to energize/ and SP10) solenoid.
actuate the pressure vessel valve solenoid/ (5). Loosen nut at outlet port of solenoid
squib) to the emergency float circuit. valve. Disconnect valve assembly from
Internal light bulbs in the switch will illu- union by unscrewing cylinder and valve
minate if the circuit is operational. assembly in counterclockwise direction.
Remove cylinder and valve assembly.
(b). Observe that each switch faceplate is
illuminated when pressed and goes (6). If cylinder is not empty, discharge as
out when switch is released. follows:
Exercise care when dis-
NOTE: Failure to illuminate indicates a bur- WARNING charging cylinder. Person-
nedout light bulb in the switch or a defec-
nel can be injured by high pressure air
tive circuit. Extreme brightness indicates a
or flying debris.
defective circuit.
(a). Secure cylinder in chain vise or
(2). Check each pressure vessel for proper equivalent. Point filler valve outlet in
(normal) air pressure, 3500 psig (24132 safe direction.
kPa) at 70F (24C).
(b). Use two open end wrenches, one on
8. Float Compartments Pressure Test filler valve body and one on nut. Turn
nut slowly counterclockwise 21/4
(1). Inflate all five float compartments to turns and allow all pressure to
2.0 psi (14 kPa) and let stand for 24 escape. Check gage to verify that no
hours. pressure remains in cylinder.
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MAINTENANCE MANUAL
(7). Remove solenoid valve from cylinder. 3). Install one lead of 0.5 ohm 5%,
Discard solenoid valve and packing. 10W resistor in pin A of left-hand
connector (P101). Connect one test
(8). Install new squib valve (PN 231113803 lead of ammeter (VOM) to other
LH float, PN 231113804 RH float) with lead of resistor. Connect other test
PN MS2877812 packing on cylinder. lead of ammeter (VOM) to pin D of
Torque to 360 504 inch pounds connector (P101).
(40.67 56.95 Nm) (Ref. Figure 403).
4). Close emergency float circuit
(9). Install fitting with PN MS287786 breaker (CB121).
packing on existing union.
5). Press PRESSTOTEST switch
(10). Recharge cylinder and test for air leaks. and observe current reading on
ammeter and brilliance of lamps.
(11). Install charge cylinder and squib valve Current should be 75 MA mini-
assembly with PN MS287786 packing mum and brilliancy of lamps
on fitting. should be fairly bright.
(12). Revise emergency float electrical 6). Open emergency float circuit
system as follows: breaker (CB121).
7). Remove meter and resistor from
(a). Remove access panels and/or covers connector (P101).
as necessary to expose emergency
float wiring. 8). Repeat steps 3). through 7). for
right-hand connector (P102).
(b). Remove all emergency float wiring
except as noted in Figure 903. (b). System check;
(c). Remove and discard relay installa- 1). Ensure that circuit breaker
tion, doubler and attaching hardware (CB121) is open and connectors
located on pilots floor support, left (P101 and P102) are disconnected.
bulkhead. 2). Install one lead of 40 ohm 1%,
20W resistor in pin A of left-hand
(d). Remove emergency float switch light
connector (P101) and install other
assembly and install new switch light
lead of resistor in pin D of connec-
assembly.
tor (P101).
(e). Install wiring as shown in 3). Connect test leads of voltmeter
Figure 902. Do not plug in electrical (VOM) across resistor.
connectors (P101 and P102) until
after electrical system check. 4). Close emergency float circuit
breaker (CB121).
(f). Reinstall access panels and/or covers.
5). Press firing switch on pilots grip
(13). Turn on electrical power. and observe voltage on meter.
Voltage should be 25.5 Vdc mini-
(14). Perform inflation system electrical mum.
control equipment operational check as
follows: 6). Open circuit breaker (CB121).
7). Remove meter and resistor from
(a). Test light check; connector (P101).
1). Check ship voltage with VOM. 8). Repeat steps 2). through 7). for
Voltage should be 27.5 Vdc. right-hand connector (P102).
2). Open emergency float circuit (c). Connect connectors (P101 and P102)
breaker (CB121). to squib valves.
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MAINTENANCE MANUAL
(d). Close emergency float circuit breaker (16). Repack emergency floats (Ref.
(CB121). Figure 404).
(e). Press PRESSTOTEST switch and
observe that lamps light. (17). Remove existing VNE cards (solenoid
valve, floats stowed (3) and solenoid
(f). Open circuit breaker (CB121). valve, floats inflated (1)).
(15). Ensure that cylinder is positioned so
that pressure gage is visible through (18). Install PN 369D29257449, 51 and
inspection window when floats are 53 VNE cards (squib valve, floats
stowed, pressure gage axis inclined stowed) and PN 369D29257319 VNE
outboard approximately 40. card (squib valve, floats inflated).
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MAINTENANCE MANUAL

1. Emergency Float Replacement NOTE: If extension tubes are not installed on
helicopter, refer to Skid Tube Extension Re-
A. Emergency Float Removal placement.
(Ref. Figure 401) (2). Position float girts over skid tube
attach points.
(1). If float is in stowed configuration,
release fasteners to gain access to float (3). Temporarily attach float web support
package. strap fittings at forward location;
Secure strap fitting at aft attach
(2). Detach lower restraining strap and gap location with bolts and washers.
cover at forward and aft struts.
(4). Place gravel guards over float girts and
(3). Disconnect solenoid valve electrical secure with bolts and washers. Torque
wiring at knife splice at solenoid valve all bolts securing float girts to skid
or disconnect squib valve electrical tubes to 25 35 inchpounds (2.82
connector at squib and install shunt. 3.95 Nm).
(4). Remove strut fairing, insulate strut (5). Apply zinc chromate putty (CM209) to
wire end knife splices, attach wiring to contact surfaces of previously removed
strut in a stowed position and reinstall abrasion strips, and skid extension
fairing. abrasion strips to ensure watertight fit
on landing gear skids.
(5). Remove bolts and washers attaching for
and aft web support strap fittings to (6). Loosen float forward web strap fitting
skid tube. and position abrasion strip on skid
below strut; position web strap fitting
(6). Remove bolts and washers attaching over forward attach hole on abrasion
float girts to skid tube extension; strip and secure strip to skid with bolts
remove float assembly. and washers. Install remaining abra-
sion strips; remove excess zinc chro-
B. Emergency Float Installation mate putty.
(Ref. Figure 401) (7). Install remainder of bolts and washers
securing float girts to skid tube exten-
Consumable Materials sion.
(8). Adjust and secure float landing gear
Item Nomenclature
strut cutout restraining straps.
(9). Unsnap float containment cover and
loosen restraining lacing to gain access
NOTE: The float assembly must be removed to emergency inflation system compo-
from the stowage envelope for installation. nents.
(1). Open float package and release re- (10). Connect squib valve electrical connector
straining straps. at squib.
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MAINTENANCE MANUAL
FLOAT GIRTS
FLOAT ATTACHMENT
CONTROL
SWITCHES STOWED FLOAT
GRAVEL GUARDS
CIRCUIT SKID TUBE

BREAKERS AFT LANDING GEAR STRUT EXTENSION
NARROW FAIRING
WEB
ATTACHMENT WEB SUPPORT GIRT
STRAP
COVER PRESSURE GAGE
INSPECTION WINDOW ABRASION STRIP
SKID
COVER
ABRASION STRIP
INFLATED FLOAT
FITTING GRAVEL GUARD

(NOTE)
FORWARD LANDING GEAR
CONTAINMENT STRUT NARROW FAIRING
COVER
ABRASION STRIP
SUPPORT TUBE
GRAVEL GUARD AIR HOSE (TYPICAL)
ABRASION STRIP RETAINING STRAP
(TYPICAL)
SOLENOID
STRUTTOSKID
PRESSURE RELIEF VALVE COVER
AND FILLER VALVE ABRASION
STRIP
FOOT
PRESSURE VESSEL
FILL VALVE
GAP COVER
(TYPICAL)
MOORING MANIFOLD SKID TUBE
RING
PRESSURE
GAGE
FORWARD FOOT OUTBOARD SIDE
INLET CHECK VALVE

(TYPICAL) NOTE:
FORWARD FITTINGS ATTACHED AT FIRST NUTPLATE
PRESSURE RELIEF FORWARD OF STRUT FOOT. REAR FITTINGS ATTACHED
VALVE (TYPICAL) AT FIRST NUTPLATE AFT OF STRUT FOOT.
G328002
Figure 401. Emergency Float Installation
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MAINTENANCE MANUAL
2. Emergency Float Pressure Vessel D Squib valve: If actuated, replace with a

Servicing and Replacement serviceable valve. Install valve on pres-
sure vessel and torque to 380420
(Ref. Figure 401) Maximum allowable temper- inchpounds (42.93 47.45 Nm).
ature during charging is 165F (75C).
Detaching the pressure vessel from the float
during charging is the preferred procedure. (5). Detach restraining lacing and remove
Maximum pressure vessel pressure is 3500 pressure vessel from float.
psig (24132 kPa) at room temperature, 70F
(21C). As outside air temperature will affect (6). Recharge pressure vessel with dry
the daytoday gage reading, temperature nitrogen or compressed dry air to 3000
versus pressure readings are important during 3500 psi (20684 24132 kPa) at 75F
servicing or inspection of the pressure vessel (24C); 3500 psig (24132 kPa) at 75F
air pressure. The indicated pressure on the (24C) is preferred. Cool cylinder with
gage will increase or decrease 6.6 psig (45.5 water and charge slowly to maintain
kPa) per 1F (0.4C) increase or decrease, vessel surface temperature below 250F
respectively, in vessel air temperature. Slow (122C).
variations in ambient air temperature will be
reflected in the vessel air temperature;
however, it must be considered that direct or NOTE: The pressure vessel may also be serv-
reflected solar radiation will result in higher iced by weight. When servicing by weight,
pressure than would be anticipated for the use a scale and weigh the empty vessel with
existing ambient air temperature. attaching hardware installed. Charge the
empty vessel until a weight increase of 3.7
4.4 pounds (1.68 2.0 kg) is obtained; 4.4
0.1 pounds (2.0 0.05 kg) is preferred.
When charging by weight, air temperature
Item Nomenclature
variation will have no affect. Observe vessel
CM810 Leak detector, liquid cooling precaution.
(1). If float is stowed, unsnap containment (7). Test for air leaks by applying liquid
cover to extent required for access to leak detector (CM810) to the valve
pressure vessel. pressure vessel interface. No air
(2). Open manifold change valve to verify bubbles are permitted.
that there is no pressure remaining in
pressure vessel. (8). Dry with clean lintfree cloth and then
(3). Remove the three air hoses at air allow to airdry completely.
manifold. Do not allow the manifold to
turn when disconnecting the hoses. (9). Inspect the emergency inflation system.
(4). Disconnect solenoid valve electrical
wiring knife splice at solenoid or (10). Cover vessel with bag and tie closure
disconnect squib valve electrical lacing.
connector at squib and install plug.
Use a widestrap wrench, 2 inch (11). Reinstall vessel and bag on float;
CAUTION (5 cm) minimum width, to apply reconnect air hose fittings and
torque on the pressure vessel, taking care solenoid/squib valve electrical wiring
not to damage it. Use crowfoot adapter on knife splice/squib valve electrical
the torque wrench at the valve body. connectors. The pressure vessel must be
positioned so that air hose connections
NOTE: place no strain on the solenoid/squib
D Solenoid valve: Do not remove solenoid and the pressure gage is visible through
and relief valve assembly from pressure the pressure gage inspection window
vessel. when the floats are stowed.
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MAINTENANCE MANUAL
VALVE PROTECTOR
SOLENOID VALVE PROTECTOR
NUT
CROSS
UNION
PRESSURE VESSEL
G328003
Figure 402. Solenoid Valve Assembly
(12). Reinstall manifold cover. (4). Spread plastic cover at its parting line
until small round end of white plastic
(13). Perform an inflation system electrical buttons pull through the black plastic
control equipment reliability test. and over the squib connector, allowing
access to four screws that retain the
3. Squib and Squib Actuated Valve actuating valve body.
Replacement
(5). Using Allen wrench, remove four
(Ref. Figure 402 and Figure 403) Each time screws near the outlet port retaining
the emergency floats are inflated using the the actuated valve body. Retain screws
emergency float inflation system, the squib for installation of new valve.
and squib actuating valve must be replaced.
(6). Pull spent valve and squib off vessel.
NOTE: Solenoid valves used in the emergency Discard activated valve and squib.
float system are no longer available from the
manufacturer. Emergency float systems
(7). Lightly lubricate Oring on new valve
equipped with the solenoid valve must be
with MILG4343 or equivalent
converted to the squib valve system when
pneumatic grease.
the service life of the solenoid valve is ex-
ceeded.
The squib is an electrically
(1). Open manifold change valve to verify WARNING fired explosive. Ensure con-
that there is no pressure remaining in nector plug is installed in connector
pressure vessel. prior to installation.
(2). Remove pressure vessel with squib (8). Maintain squib orientation noted in
valve assembly attached. step (3).. Install squib actuated valve,
with squib installed, into manifold.
(3). Note orientation of squib with respect Squib actuated valve must bottom
to pressure gage. metaltometal on face of manifold.
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MAINTENANCE MANUAL
SQUIB
OUTLET
SCREW
VALVE BODYTO
MANIFOLD JOINT
TAVCO
FITTING
PRESSURE VESSEL
ATTACHMENT
PRESSURE GAGE
SQUIB VALVE
CONNECTOR
BENDIX
PRESSURE
VESSEL
PACKING SQUIB VALVE ASSY (LH)
SQUIB VALVE ASSY (RH)
FITTING NUT
PACKING UNION CROSS

PACKING
SQUIB VALVE ROTATED AND INSTALLED IN PRESSURE VESSEL
G328006A
Figure 403. Squib Valve Assembly
Page 405
328200 Revision 19
MAINTENANCE MANUAL
(9). Install four screws removed in step e. cover, all snaps must be closed and the
hand tight until locking thread of pressure vessel pressure gage must be
helicoil insert in manifold is engaged. visible in the inspection window.
Special attention should be paid to the
(10). Using Allen wrench, tighten the four following information which is pres-
screws evenly until bottomed. Torque ented as an aid in establishing a final
screws to 38 43 inchpounds (4.29 float folding technique.
4.86 Nm).
(a). Accomplish float folding in two
(11). Remove plug from squib connector.
stages, first performing float arrange-
Note that plug only fits one way.
ment (prefolding) to the extent
Realign black plastic cover and pull it
necessary to position the float and
back over the squib connector. Replace
float components in approximate
squib connector plug.
required positions and then proceed-
(12). Snap white plastic buttons back ing with the final folding.
through holes in black plastic cover.
Check plug in squib connector to ensure NOTE: Partial inflation of float compartments
it is bottomed. is required to enable float arrangement dur-
ing initial prefolding.
(13). Charge pressure vessel and reinstall on
emergency float assembly. (b). During prefolding and before air
evacuation of the forward compart-
4. Emergency Float Folding ments (cells) as outlined in step 4, do
the following. Gather and compress
(Ref. Figure 404) Folding instructions con- the float fabric tightly against the
tained in this procedure are provided as a vessel and pull the cover over the
general guide for float packing. Float folding inboardfacing pressure gage to
will require the aid of an assistant and estimate final cover windowtogage
considerable care in preparing the smallest relationship. This fabric bunching/
float package possible during the initial folding cover pulling action may be required
steps. A minimum amount of wrinkles and several times before an approxima-
complete air evacuation is essential to final tion (best guess) of final window
closure of cover snap fasteners. position is established. When cover
(1). Position deflated float (five fill valves position appears good, evacuate all
OPEN). air from the forward cells and
recheck the windowtogage rela-
NOTE: The float assembly must be removed tionship.
from the stowage envelope for installation.
Do not attempt to position the float for pack- (c). As soon as a float chamber is ar-
aging with the float chambers fully col- ranged in the desired position, hold
lapsed. the components in place, flatten as
many wrinkles as possible and
(2). Fold the float as outlined in the figure. evacuate air from the float chamber.
On completion, the folded float must be While the vacuum is still being
contained within the float stowage applied, close the fill valves.
Page 406
Revision 19 328200
MAINTENANCE MANUAL
STEP 7
FOLD HERE
STEP 2
LANDING GEAR AFT
STRUT (REF)
LANDING GEAR STEP 3

FORWARD STRUT
(REF)
STEP 5 SKID TUBE
EXTENSION
(REF)
STEP 8
STEP 10 AND 11
STEP 4
STEP 6
STEP 1
STEP 9
FOLD HERE
LANDING GEAR SKID (REF) G328005
STEP 1 OPEN ALL FILL VALVES OF INFLATED FLOAT AND COMPRESS CELLS LIGHTLY BY HAND SO THAT FLOAT IS FLAT
AND AS SMOOTH AS POSSIBLE.
STEP 2 PLACE FOLD AT AFT END OF SKID EXTENSION THEN EVACUATE AFT OUTBOARD AIR COMPARTMENT (CELL)
UNTIL FOLD IS FIRM AND SHARP. CLOSE FILL VALVE.
STEP 3 WHILE COMPRESSING SUPPORT TUBE AND HOLDING FLOAT CENTER FORWARD AND DOWN, PLACE A FOLD IN
INBOARD CENTER CELL BETWEEN INLET CHECK VALVE AND FILL VALVE. REARRANGE AIR HOSE AS REQUIRED.
CONTINUE HOLDING PRESSURE ON SUPPORT TUBE. EVACUATE CENTER CELL THEN AFT INBOARD CELL UNTIL
FOLDS ARE SHARP AND SUPPORT TUBE IS FIRMLY HELD FROM MOVING AFT. CLOSE FILL VALVE.
STEP 4 POSITION PRESSURE VESSEL SNUG AGAINST OUTBOARD SIDE OF FORWARD STRUT. WHILE HOLDING VESSEL IN
POSITION, EVACUATE FORWARD OUTBOARD CELL THEN FORWARD INBOARD CELL UNTIL CREASES ARE FIRM
AND SHARP. CLOSE FILL VALVE.
STEP 5 RECHECK FLOAT. CHECK THAT FLOAT IS AS FLAT AS POSSIBLE AND FREE OF ALL AIR POCKETS. DOUBLE CHECK
FIRMNESS OF ALL CREASES AND REEVACUATE CELLS AS NECESSARY.
NOTE: ANY REMAINING AIR MIGHT CAUSE FLOAT OPENING AT ALTITUDE AND DIFFICULTY IN PACKING.
STEP 6 FOLD FLOAT AFT AT FORWARD END. REPOSITION HOSES AS REQUIRED. STOWAGE COVER MUST BE OUTSIDE
OF FOLD LINE.
STEP 7 FOLD FLOAT FORWARD AT AFT END. REPOSITION AIR HOSES AS REQUIRED. STOWAGE COVER MUST BE
OUTSIDE OF FOLD LINE.
STEP 8 ROLL AND FOLD LENGTH OF FLOAT TOWARDS CENTER. DO NOT COVER PRESSURE GAGE.
STEP 9 ROLL AND FOLD LENGTH OF FLOAT TOWARDS CENTER. FASTEN SNAPS STARTING AT FORWARD END. ENSURE
THAT PRESSURE GAGE IS VISIBLE IN INSPECTION WINDOW. DO NOT FASTEN END COVER SNAPS.
STEP 10 TIGHTEN LACING. ENSURE THAT SNAP FASTENERS REMAIN CLOSED.
STEP 11 SECURE END COVER SNAPS. ALL SNAP FASTENERS MUST BE USED.
Figure 404. Emergency Float Folding

328200 Revision 19
MAINTENANCE MANUAL

1. Emergency Float System Initial (a). Ensure that all flight compartment
Installation switches are in OFF position.
A. General CAUTION
Make certain BATTOFFEXT
switch is in OFF position.
Procedures in this section may be performed at
the operators discretion. Instructions are (2). Remove landing gear strut fillets and
provided for installation of emergency float kit fairings (Ref. Sec. 321000). Retain all
on either the current or early configurations of doublers, guides, pins and springs for
the extended landing gear. Subsequent reinstallation.
installation instructions for the emergency (3). On current configuration landing gear,
floats and the float electrical control system remove forward nut, bolt and spacer
are identical for the current and early ex- attaching existing extension to aft end
tended landing gear configurations. Equip- of skid tube; retain nut for reinstalla-
ment removal and modification differences tion.
between the current and early configurations
are noted in the subsequent instructions. (4). On early configuration landing gear,
remove abrasion strip attached to
The emergency float kits are provided with as existing skid tube extension (Ref. Sec.
many assembled parts as practicable to 321000).
facilitate initial installation on the helicopter.
Installation of electrical equipment assumes (5). Remove screws and bolts securing skid
prior incorporation of pilots cyclic stick grip tube extension; retain early configura-
kit (369D90129507 or 369D90129511). tion indexing plugs for reinstallation.
B. Initial Preparation (6). Remove skid abrasion strips below for

and aft fairings; retain abrasion strips
Instructions in the following paragraphs are for reinstallation.
applicable to both left and right landing gear
D. Landing Gear Skid Extension Assembly
assemblies. Prepare the aircraft for installa-
tion of emergency floats as follows: (Ref. Sec. 328100)
NOTE: When installing emergency floats, the E. Emergency Float System Electrical
VNE cards must be replaced with the cards Equipment Installation
that come with the floats (Ref. appropriate
PFM). (Ref. Figure 901)
(1). Identify all components, including (1). Remove attaching hardware and
attaching hardware, and components separate lower switch and circuit
removed for access to work areas. breaker panel from instrument panel
Protect components from damage and structure.
contamination until installed. (2). Remove covers from emergency float
presstotest switch and circuit
(2). Raise aircraft clear of ground; Use breaker cutouts from lower switch and
authorized hoisting or jacking methods circuit breaker panel.
(Ref. Sec. 070000). Place support
beneath skid tubes at strut locations. (3). Install emergency float circuit breaker
in panel.
C. Existing Equipment Removal
NOTE: Presstotest switch is installed during
(1). Remove Battery (Ref. Sec. 960500). subsequent wiring installation procedure.
Page 901
328200 Revision 19
MAINTENANCE MANUAL
PILOTS CYCLIC
STICK GRIP
GROMMET
FLOAT
SWITCH
CLIP
FLOAT
SWITCH
FORWARD STRUT OPTIONAL T GRIP STANDARD GRIP
DOUBLER MOUNTING
SLEEVE
PILOTS FLOOR SUPPORT EXITING
FORWARD LEFT BULKHEAD HOLE SWITCH
HOUSING
LAMP (4)
RELAY LOCKING INDICATOR

BRACKET CAM MODULE
LOCKING CAM LEGEND
SCREW (2) FACE
RELAY
SWITCH INSTALLATION
PILOTS FLOOR SUPPORT (SLIMLINE PANEL)
FORWARD LEFT BULKHEAD
CIRCUIT
BREAKER
FLOAT
PRESSTOTEST
INSTRUMENT PANEL (COMM. T PNL.) VIEW
LOOKING FORWARD
G328007A
Figure 901. Emergency Float Kit Electrical Installation
Page 902
Revision 19 328200
MAINTENANCE MANUAL
F. Emergency Float System Electrical (6). Install wiring through landing gear
Wiring Installation struts as follows:
(Ref. Figure 902 thru Figure 905) (a). Drill 0.442 inch (11.2268 mm) hole
centered on outboard side of forward
struts located five inches (12.7 cm)
Consumable Materials above centerline of skid tube; deburr
(Ref. Section 910000) holes internally and externally.
Item Nomenclature
CM318 Primer (b). Coat bare metal in holes with primer
(CM318); allow primer to dry.
CM601 Insulation sleeving, electrical
(c). Remove left and right foot support
fairing in passenger compartment for
(1). Identify wires as required and form access to landing gear forward struts.
wire bundle of applicable wires to
emergency float circuit breaker and (d). Install insulation sleeving on float
presstotest switch on lower switch valve squib wires.
and circuit breaker panel.
(e). Locate position light wire bundle exit
(2). From battery compartment area, route holes on top inboard portion of left
wire bundle forward and up through and right landing gear struts; Insert
instrument panel support structure; respective float squib wire bundles
route wire bundle with existing bundles through position light wire bundle
where possible. exit holes. Locate wires through
previously drilled wire exit hole at
(3). Install insulation sleeving (CM601) and bottom of each strut. Carefully pull
connect applicable wires to contacts on wires through holes allowing suffi-
presstotest switch and circuit cient length for connections at either
breaker; assemble and secure pressto end.
test switch to panel.
(f). Slide grommet over wire bundle on
(4). Adjust wire bundle and allow sufficient both struts; Install grommet in
slack for maintenance; strap and string previously drilled wire exit holes.
tie bundle to form smooth flow of wires
(g). Attach clip (Ref. Figure 901, view G).
to battery compartment area.
(h). Coil and stow wires to avoid damage
(5). Ensure all switch and circuit breaker during float equipment installation.
contacts are secure and that sleeving is
properly installed; remove paint from (7). Complete balance of all wiring. Install
panel and console in upper screw area insulation sleeving as required to
to ensure good ground contact. Install prevent shorting and chafing through-
panel on console. out circuit wiring.
Page 903
328200 Revision 19
MAINTENANCE MANUAL
NOTES:
1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE
ELECTRICAL SYSTEM WIRING DIAGRAM IN CSPHMI3
FOR COMPLETE CIRCUIT IDENTIFICATION.
2. DASHED LINE ( ) ITEMS ARE PART OF HELICOPTER
BASIC ELECTRICAL SYSTEM, UNLESS OTHERWISE NOTED.
3. PART OF SOLENOID FLOAT VALVE.
4. ENDS OF WIRE A507B20 (PART OF BASIC ELECTRICAL
SYSTEM) MUST BE DISCONNECTED AND INSULATED.
G328013A

(369D290121501 and 505)
Page 904
Revision 19 328200
MAINTENANCE MANUAL
RED OR YELLOW
BLACK OR BLUE
TB115
A A (NOTE 2)
SP3 A B C D
B B
SP9
PILOTS INFLATE FLOAT SWITCH
SQUIB FLOAT
P102 VALVE R.H.
S5
M512A20N
1 2 E2 B
369H9012950 5 (NOTE 2) D
5 GRIP (REF) M509B20 C
3 4 17.20
FOR (NOTE 3) M9251811 A
12.20 18.20 11.20 (NOTE 3)
369H92557511 SEE SPLICE
16.20 15.20 SQUIB FLOAT
SHEET 2 FOR (NOTE 3) 4 REQD
JUMPER GA.20 VALVE L.H.
369H92557513 J130 B J H N D M
8 REQD P101 BENDIX PLUG
(NOTE 1) M510B20
(NOTE 3) MS 25036103 (NOTE 2) A
M521E20 E5
TERMINAL 2 M511AN20 C
M508B20 REQD D121 E2 D
MPCM20MH2 (NOTE 2) B
PIN 1 REQD SOLDER SLEEVE 80
P506M20 REQD 2.0 MAX BENDIX PLUG
EMERGENCY M506M20 CABLE P/N PT06P84S
TB118 C A
FLOAT SYSTEM RNF 100X1/4 SLEEVE
BUS WIRE TB101 (REF)
(A/R LH AND RH
28 V. BUS
TB19 SIDES)
3 (REF)
E2
MS 25036103 BLACK OR BLUE
TERMINAL
M506A20 M506N20
NO
CABLE (REF) (S3)
1 2 C
CB121 NC
(NOTE 2)
7.5A
2TC137.5 CIR. BRK NO
(S2)
MS 25036149 M506H20
C NC
TERMINAL
FOR511
NO
(NOTE 1) RED OR YELLOW (S1) R1
C NC
MS 25036149
TERMINAL 2 REQD
7.5A MS 252447.5
1 2 CIRCUIT BRK. R2
CB111 P506M20
4 1 5
EMERGENCY FLOAT 2
SYSTEM BUS WIRE
28V. BUS CB118

(REF) (REF) L.H. R.H.
FOR513
(NOTE 1)
3
369H9255761
SWT/LT ASSY
SYSTEM TEST PRESS
NOTES: PARTS REQUIRED:
1. EXISTING EMERGENCY FLOAT SYSTEM WIRING. DO NOT REMOVE. JUMPER #22 GA. 4 REQD
2. SHIELDS TO BE TERMINATED 0.50 INCH (12.70 MM) MAX. FROM END 3/16 PD CAPS 4 REQD
OF INSULATION ON WIRE (EXCEPT AS NOTED). JUMPERS TO BE 32445 SPLICE 4 REQD
MIN. LENGTH. SLEEVING A/R
3. REMOVE WIRE A510A20 FROM PIN J130H, M521C20 FROM PIN MS 25036103 TERMINAL 2 REQD
J130D, A507A20 FROM PIN J130M, A506B20 FROM J130N AND MPCM20MH2 PIN 2 REQD
STOW WITH 3/16 PD CAPS. D121 SOLDER SLEEVE 2 REQD
G3280141B

(369D290121515, 517 and 519) (Sheet 1 of 2)
Page 905
328200 Revision 19
MAINTENANCE MANUAL
S5
1 2
20 GA
369D297846 GRIP
(REF) 3 4
1220 1620 1820 1520 1120 1720

SP101 SP103 SP106 SP105 SP104 SP102
J109 B B B B B B
(REF) A A A A A A
32445 SPLICE
10 REQD
E5
M506C20 M506G20 RED OR BLACK OR BLACK OR RED OR
YELLOW BLUE BLUE YELLOW
MPCM20MH2 PIN TB18 TB19
C A
M506M20 CABLE
(REF)
M506N20 (REF)
SP3 A A B C D A SP9
TB115 (REF)
FOR 369H92557513
(NOTE 1)
BLACK
5 1 4 M506N20
2 3
CABLE
(NOTE 2)
NC NC NC
(NOTE 2)
NO NO NO
RED
C C C
MPCM20MH2 PIN 1 REQD
MS 25036103 TERMINAL 1 REQD
(S93) (S92) (S91) D121 SOLDER SLEEVE 2 REQD
JUMPER #22 GA
R.H. FLOAT (REF) L.H. FLOAT (REF)
M506H20
369H9255761 SWITCH LIGHT ASSY

G3280142A

(369D290121515, 517 and 519) (Sheet 2 of 2)
Page 906
Revision 19 328200
MAINTENANCE MANUAL
G3280151

(369D290121521, 523, 525 and 527) (Sheet 1 of 2)
Page 907
328200 Revision 19
MAINTENANCE MANUAL
G3280152

(369D290121521, 523, 525 and 527) (Sheet 2 of 2)
Page 908
Revision 19 328200
MAINTENANCE MANUAL
NOTES:
1. DASHED LINES ( ) ARE PART OF
BASIC SHIP WIRING.
2. EFFECTIVE ON HELICOPTERS
369E S/N 384 AND SUBS.
369FF S/N 076 AND SUBS.
500N S/N 001 AND SUBS.
G328017
Figure 905. Emergency Float Installation with Generic Wire Harness
Page 909
328200 Revision 19
MAINTENANCE MANUAL
G. Emergency Float Electrical System Ensure that the BATTOFF

Inspection CAUTION EXT switch is in the OFF posi-
tion.
Before connecting battery plug, the following
wiring installation inspection must be per- H. Emergency Float System Strut Fairing
formed. Installation
(Ref. Figure 906)
(1). Inspect all wiring connections for
security and insulation.
(2). Inspect all wiring for interference with (Ref. Section 910000)
moving parts and for areas where Item Nomenclature
chafing could occur. CM209 Zinc chromate putty
(3). Inspect all wiring for conformance with

wiring diagrams. The following installation instructions are
typical for all four strut fairing assemblies.
(4). Install all access panels, doors and Where riveting is required, Refer to referenced
access covers previously removed. instructions for proper rivet types.
(1). Install center fairing, fillet and lower
(5). Remove insulation and temporarily fairing in respective order, and general-
connect each set of float squib wires. ly in accordance with instructions (Ref.
Sec. 321000).
(6). Install battery, connect battery plug
and place BATTOFFEXT switch in (2). During installation of fairings, ensure
BATT position. that doublers, removed during disas-
sembly, are installed between fairings
(7). Momentarily press emergency float and fillers at screw attach points.
presstotest switch to verify proper
wiring continuity; all four switch lamps (3). Ensure blocks are installed at lower
should illuminate. trailing edge of fillets to ensure free
action of fillet with strut movement.
(8). Separate float squib wires at base of (4). Ensure that float solenoid/squib wire
struts. bundles are free at bottom of lower
fairings on forward struts.
(9). Actuate EMERG/FLOAT switch on
pilots cyclic stick grip; use voltmeter to (5). Install bolt covers over inboard bolt
check for proper voltage and continuity heads on strut foot/skid attach point.
through float squib valve circuits. Apply sufficient zinc chromate putty
(CM209) to fill all voids between cover
(10). Pull out emergency float circuit breaker and bolt head area; secure forward
to remove power and release relay; strut bolt covers with existing nylon
push circuit breaker in again to prepare hardware. Torque screws to 25 35
circuit for emergency use. inchpounds (2.82 3.95 Nm).
Page 910
Revision 19 328200
MAINTENANCE MANUAL
DOUBLER
FAIRING
NUTPLATE
WASHER
CHAFING PAD DOUBLER
SCREW
(FORWARD FAIRING)
FAIRING
TEFLON STRIP (FORWARD
FAIRING) 0.50 IN. 0.50 IN.
RIVET
FILLET 1.25 IN.

FILLER
BLOCK
FILLERTOFAIRING
ATTACHMENT (TYPICAL)
CENTER FILLER
FAIRING
CENTER NUTPLATE
FAIRING DOUBLER
FAIRING WASHER
FAIRING
MOUNTING SCREW
BRACKET DOUBLER
LOWER FAIRING
LANDING SCREW FILLER
GEAR
STRUT
CENTERTOLOWER FAIRING FILLER

ATTACHMENT
LOWER FAIRING
STRUTTOSKID STRUT FOOT

BOLT COVER
STRUT FOOT
FOOT SKID TUBE STRUTTOSKID

CONTAINMENT BOLT COVER
COVER
SKID
SEAL
NYLON SCREW
BOLT COVER INSTALLATION
G328016
Figure 906. Emergency Float System Strut Fairing Installation
Page 911
328200 Revision 19
MAINTENANCE MANUAL
I. Emergency Float Installation (6). Loosen float forward web strap fittings
and position abrasion strip on skid
below strut; position web strap fitting
over forward attach hole on abrasion
Item Nomenclature
strip and secure strip to skid with bolts
and washers. Install remaining abra-
CM209 Zinc chromate putty sion strips; remove excess zinc chro-
mate putty.
Installation of the left and right emergency
floats is identical except for opposite positions. (7). Install balance of bolts and washers
securing float girts to skid tube exten-
(1). Open float package and release re- sions. Torque all bolts to 25 35
straining straps. inchpounds (2.82 3.95 Nm).
(2). Position float girts over skid tube
attach points. (8). Adjust and secure float landing gear
strut cutout restraining straps.
(3). Temporarily attach float web support
strap fittings at forward location; (9). Unsnap float containment cover and
secure strap fitting at aft attach loosen restraining lacing to gain access
location with bolts and washers. to emergency inflation system compo-
nents.
(4). Place gravel guards over float girts and
secure with bolts and washers.
(10). Connect squib valve electrical connector
(5). Apply zinc chromate putty (CM209) to at squib.
contact surfaces of previously removed
abrasion strips, and skid extension (11). Perform inspection of emergency float
abrasion strips, to ensure watertight fit inflation system (Ref. Emergency Float
on landing gear skids. Inspection Stowed Configuration).
lbs (kg) in. (cm) in.lb/100 (kgmm/100)
501 +151.7 (+68.872) 95.9 (243.59) +145 (+1670.57)

505 +150.8 (+68.463) 96.0 (243.84) +145 (+1670.57)
515 +129.1 (+58.611) 99.1 (251.71) +128 (+1474.71)
517 +127.7 (+57.976) 98.9 (251.21) +126 (+1451.67)
519 +152.7 (+69.326) 96.4 (244.86) +147 (+1693.62)
521 +152.6 (+69.280) 96.5 (245.11) +147 (+1693.62)
523 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
525 +127.5 (+57.885) 99.0 (251.46) +126 (+1451.67)
527 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
529 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
531 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
Page 912
Revision 19 328200
MAINTENANCE MANUAL
Chapter
52
Doors
MAINTENANCE MANUAL
TABLE OF CONTENTS
521000 Crew, Passenger, Cargo Doors and Windows . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Crew and Passenger/Cargo Door Description and Operation . . . . . . . . . . . . . . . . . . . 201
A. Early DoorLatching System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Current Door Latching System (HookLatch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. HookLatch Automatic Door Latching System Troubleshooting . . . . . . . . . . . . . . . . 202
Table 201. HookLatch Automatic Door Latching System Troubleshooting . . . 202
3. Crew Compartment Door Replacement (369D/E/FF 500/600N) . . . . . . . . . . . . . . . 203
A. Crew Compartment Door Removal (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . 203
B. Crew Compartment Door Installation (369D/E/FF 500/600N) . . . . . . . . . . . . . . 203
4. Passenger/Cargo Compartment Door Replacement (369D/E/FF 500N) . . . . . . . . 203
A. Passenger/Cargo Compartment Door Removal (369D/E/FF 500N) . . . . . . . . . . 203
B. Passenger/Cargo Compartment Door Installation (369D/E/FF 500N) . . . . . . . 203
5. Mid and Aft Door Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Mid and Aft Door Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Mid and Aft Door Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Door Seal Compression Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Crew and Passenger/Cargo Door Installation (Sheet 1 of 2) . . . . . . 204
7. Mid and Aft Door Strut Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Mid and Aft Door Strut Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Mid and Aft Door Strut Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Snapvent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Snapvent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Snapvent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9. Outside Handle or Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Outside Handle or Spindle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Outside Handle or Spindle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10. Automatic Latch Block Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Automatic Latch Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Automatic Latch Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
11. Cam Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Cam Lock Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Cam Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12. Latch Assembly or Striker Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Door Seal Compression Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Door Latching System Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . 208
Page i
MAINTENANCE MANUAL

B. Engagement Depth of Latch Bolts with Striker Adjustment . . . . . . . . . . . . . . . . . 210
C. Connector Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
D. Latch Compression Adjustment (Early System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
13. Latching Mechanism Operational Check (Early System) . . . . . . . . . . . . . . . . . . . . . . 210
14. HookLatch Door Latching System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 203. Door Handle Positions and Latch Engagement (Sheet 1 of 3) . . . . . 211
15. Autolatching Pilot and Cargo Doors Operational Check . . . . . . . . . . . . . . . . . . . . . . . 213
16. DoorLatching Mechanism Inspection (All Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . 214
17. AntiChafing Tape on Door Frame Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
18. Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
A. Early Style Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
B. Current Style Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
19. Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
A. Preload Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 204. Door Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 205. Window and Hinge Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 206. Current Style Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
B. Rubber Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
20. Automatic Latch Block Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
21. Strike Pin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
22. Litter Door Inspection (50 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 1 of 2) . . . . . . . . 220
Figure 208. Door Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
23. Pilot and Cargo Door Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
A. Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
B. PartiallySeparated Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
24. Improved Door Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Figure 209. Improved Door Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
524000 Engine Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine Access Door General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Access Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Engine Access Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Engine Access Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Engine Access Door Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Engine Access Door Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Sheet Metal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

B. Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Catch/Latch Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Engine Access Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Engine Access Doors (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
525000 Miscellaneous Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Access and Inspection Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. General Access Doors Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Pilot Compartment Floor Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Pilot Compartment Floor Access Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Pilot Compartment Floor Access Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Pilot Compartment Floor Access Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Access and Inspection Provisions Information . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Access and Inspection Provisions and Locations (369D/E/FF)
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Access and Inspection Provisions and Locations (500N)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Access and Inspection Provisions and Locations (600N) . . . . . . . . . . 209
Figure 204. Floor Access Covers and Engine Bypass Door (600N) . . . . . . . . . . . . 210
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MAINTENANCE MANUAL

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MAINTENANCE MANUAL
Section
521000
Crew, Passenger,
Cargo Doors and
Windows
MAINTENANCE MANUAL
CREW, PASSENGER, CARGO DOORS AND WINDOWS

1. Crew and Passenger/Cargo Door The latch sliders are interconnected to rods
Description and Operation and clevis devices and are moved by turning
inside or outside door handle.
The pilot and passenger/cargo doors are
bonded aluminum alloy frames containing Movement of either handle into safelock
large smokegreytinted cast acrylic windows. position is prevented until door is closed and
Plastic snapvents are installed in each door safelock position is prevented until door is
window. An acrylic stop, bonded to the doubler, closed and safelock triggers are actuated by
prevents normal airflow from pulling the the strikes. This actuation causes the safelock
snapvent from the window during flight. These triggers to clear notches on latch sliders,
units may be rotated for intake or exhaust of allowing the latch sliders and linkage to move
ventilating air and may be pulled inward for into safelock position.
complete closure. Damaged snapvents should
be replaced, (Ref. Snapvent Replacement); B. Current Door Latching System
repair is not practical. (HookLatch)
Pilot and passenger/cargo doors are equipped Current door latching mechanisms used on
with an automatic latching mechanism. Two pilot and passenger/cargo compartment doors
door hinges on each door are provided with consist of four hook type latches mounted on
quickremoval type balllock hinge pins. the door frame. The four latches are actuated
by latch sliders which are synchronized and
Pilot and passenger/cargo doors are equipped connected by steel connector rods to the door
with automatic latching mechanisms. The handle.
latching mechanisms permit the door to be
closed and safelocked from inside or outside. With the door handle at the rest position, the
Each installation contains a keyoperated cam door may be firmly shut and the hooks will
lock, actuated from outside. Opening door from ride up over and engage their striker pins.
inside overrides keyoperated cam lock. Pilot Safelocking is accomplished by moving the
and cargo door latching mechanisms are door handle to the lock position, which causes
essentially the same except for length of the latch slider that operates each hook latch
interconnecting rods. to engage a pin within the latch block,
A. Early DoorLatching System preventing further movement until the handle
is moved to the open position. When the
Early mechanisms, installed within the door handle is moved to the open position, the latch
panel, consist of four latch blocks that house sliders fully extend the latch hooks from their
springloaded latch bolts and safelock triggers latch blocks, disengaging them from their
together with latch sliders. striker pins and allowing the door to open.
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MAINTENANCE MANUAL
2. HookLatch Automatic Door Latching

System Troubleshooting
Table 201. HookLatch Automatic Door Latching System Troubleshooting

Problem Probable Cause Repair
Hooks fail to engage striker Door seal swollen or bonding Repair seal (Ref. Door Seal Repair).
pin, or more than 0.050 inch to door frame failed.
(1.27 mm) gap between latch
hook and striker pin (Latch Striker assembly mounted too Loosen striker assembly mounting screws and
hooks extend normally). far inboard or outboard on adjust striker assembly position.
door frame.
Latch block assembly too far Add or remove 0.063 inch (1.60 mm) and
from striker pin. 0.032 inch (0.81 mm) washers as shims under
latch block mounting screws, as required (1).
Remove or add shims under striker assembly,
as required.
Striker assembly hitting or Route out waffle enough to clear.
rubbing on door waffle.
Striker assembly hitting latch Check latch covers for dents or chipped paint
cover (2). that indicates contact between latch cover and
striker assembly. Remove material from latch
cover to allow striker assembly clearance.
Latches fail to extend from Latch hooks or latch sliders Lubricate latch block moving parts.
latch block when handle sticking in latch block.
moved to open position.
Connector rod(s) improperly Adjust connector rod(s) by removing clevis
adjusted. from sliding cam and raising or lowering
threaded connector as required on threaded
portion of rod. Threads of rod and connector
must be engaged through solid portion of
connector. Rod end may be flush with or
extend beyond bottom, of solid part of
connector.
Connector rod bent or Check connector rods and clevis. Replace

damaged. damaged part.
Door does not safelock when Connector rod(s) improperly Check witness hole in latch blocks.
door handle is moved to lock adjusted. Semicircle cutout in each latch slider must be
position. fully seated around pin when safe locking is
engaged. Adjust connector rods until correct
pin engagement is achieved for each latch
slider.
NOTES:
(1) If latch block protrudes beyond middle line or door after shimming, slot mounting holes in latch block
cover 0.20 inch (5.08 mm) downward from center of existing hole to allow cover to shift up above middle
line of door waffle.
(2) Door should be closed from inside helicopter to determine if striker pin assembly is hitting or rubbing latch
cover. Enough force can be applied when closing door from outside to prevent detection of contact
between striker pin assembly and latch cover.
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3. Crew Compartment Door Replacement (4). Resafety from top hinge pin.
(369D/E/FF 500/600N)
(5). Install interior trim covers.
(Ref. Figure 201)
5. Mid and Aft Door Replacement (600N)
A. Crew Compartment Door Removal
A. Mid and Aft Door Removal (600N)
(369D/E/FF 500/600N)
(1). Remove nuts and washers from door
(1). Remove cover plates from interior trim hinge bolts.
forward of crew doors.
(2). While supporting door, slide bottom
(2). While supporting door, turn hinge pins bolt, and then top bolt from hinges.
to unlock the tabs.
(3). Remove door from helicopter.
(3). Remove lower pin, then remove top pin.
B. Mid and Aft Door Installation (600N)
(4). Remove door from helicopter.
(1). Position door so doormounted hinge
B. Crew Compartment Door Installation aligns with airframemounted hinge.
(369D/E/FF 500/600N) (2). Insert bolt, with washer, into each
(1). Slide door hinges into slots on side of hinge.
airframe. (3). Install washer and nut on bolt and
(2). Insert pins, from inside the aircraft, torque to 50 70 inchpounds (5.65
into airframe holes and though hinges. 7.91 Nm).
(3). Turn hinge pins to lock tabs into slots 6. Door Seal Compression Check
in airframe. (Ref. Figure 208) Inspect rubber weatherstrip
compression seal for tight compression
(4). Install interior trim covers.
between the door and frame as follows:
4. Passenger/Cargo Compartment Door (1). Open door.
Replacement (369D/E/FF 500N)
(2). Hold a strip of heavy paper against
A. Passenger/Cargo Compartment Door door seal so that strip extends approxi-
Removal (369D/E/FF 500N) mately 1/4 inch (6.35 mm) beyond seal
toward outside of doorway.
(1). Remove cover plates from interior trim
aft of crew doors. (3). While holding paper strip in place, close
door.
(2). Remove safety from top hinge pin.
(4). Attempt to pull paper strip from
(3). While supporting door, turn hinge pins between door frame and seal. Strip
to unlock the tabs. should not pull out unless a moderately
heavy pull is exerted.
(4). Remove lower pin, then remove top pin.
NOTE: Correct fit is indicated by an approxi-
(5). Remove door from helicopter. mate 0.060 inch (1.524 mm) interference fit
B. Passenger/Cargo Compartment Door between door seal and bumper. Where strip
Installation (369D/E/FF 500N) can be withdrawn with a light pull, fit of
door against frame is not sufficiently tight
(1). Slide door hinges into slots on side of to provide an adequate seal. This condition
airframe. may be due to deterioration of weatherstrip
compression seal, deformation of door
(2). Insert pins, from inside the aircraft, frame, worn hinges or improper latching.
into airframe holes and though hinges.
(5). Repeat this procedure at approximately
(3). Turn hinge pins to lock tabs into slots 1 foot (30 cm) increments along length
in airframe. of door seal.
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521000 Revision 25
MAINTENANCE MANUAL
FUSELAGE
DOOR FRAME
SNAPVENT
PASSENGER/CARGO DOOR
(369D/E/FF 500N)
PILOTS DOOR
(369D/E/FF 500/600N)
CLEVIS PIN FUSELAGE STRUCTURE
HINGE PIN
PRELOAD SPRING
DOOR SPRING
RUBBER STOP
BUSHING
DOOR HINGE HALF DOOR STRUCTURE
G5210011
Figure 201. Crew and Passenger/Cargo Door Installation (Sheet 1 of 2)
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Revision 25 521000
MAINTENANCE MANUAL
BOLT
WASHER
SNAPVENT
WASHER WASHER
BOLT
NUT
DOOR/HINGE ATTACHMENT
(TYP) AFT DOOR
MID DOOR
MID DOOR (600N)

AFT DOOR (600N)
G5210012
Figure 201. Crew and Passenger/Cargo Door Installation (Sheet 2 of 2)
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521000 Revision 25
MAINTENANCE MANUAL
7. Mid and Aft Door Strut Replacement (2). Slip snapvent flange into window hole
(600N) at an angle of about 30 degrees to
window surface.
(Ref. Figure 201)
(3). Be sure that ends of wire stiffener are
A. Mid and Aft Door Strut Removal (600N) inside window hole.
(1). Remove nut and washer that secures 9. Outside Handle or Spindle Replacement
gas strut pivot post ball to door fitting.
(Ref. Figure 202)
(2). Remove nut and washer that secures
A. Outside Handle or Spindle Removal
gas strut pivot post ball to airframe
fitting. (1). Remove three screws and washers
securing escutcheon to door exterior.
(3). With door in open position, pull gas
strut up away from fittings to remove. (2). Drive spring pin from handle and slide
handle from spindle.
B. Mid and Aft Door Strut Installation (600N)
B. Outside Handle or Spindle Installation
(1). Insert pivot post ball fitting, at shaft
end of strut, into outboard hole in (1). Attach replacement handle to escutch-
airframe fitting and install washer and eon with handle washers. Use maxi-
nut. mum number of handle washers
possible without impeding free move-
(2). Insert pivot post ball fitting, at tube ment between handle and escutcheon.
end of strut, into hole in door fitting (2). Slide handle on spindle and secure
and install washer and nut. escutcheon to door with washers and
(3). While holding pivot post ball fitting to screws.
prevent rotation, torque nuts to 60 85 10. Automatic Latch Block Assembly
inchpounds (6.78 9.60 Nm). Replacement
(4). Adjust strut pressure after installation (Ref. Figure 202)
by carefully loosening screw at end of
strut and releasing pressure until door A. Automatic Latch Block Removal
opens fully and operates smoothly
(1). Perform this procedure with door in
through full range of travel.
open position and handles at latched
rest position.
8. Snapvent Replacement
(2). Remove screws securing latch cover.
(Ref. Figure 201)
(3). Mark lockplate/nutplate so that
A. Snapvent Removal replacement latch block can be installed
at approximately same position as latch
(1). Push snapvent outward in window that is to be removed.
(open position).
(4). Remove four screws and washers
(2). Grasp open side of snapvent and gently securing latch block to lockplate/nut-
squeeze it into an elliptical shape. plate. Note any washers found between
latch block and lockplate/nutplate.
(3). Slip snapvent out of window hole at These are adjustment shims and should
about a 30 degree angle to surface of be reinstalled at same location and
window. position at reinstallation of latch block.
B. Snapvent Installation (5). Remove cotter pin, washer and pin
securing rod end clevis to latch block.
(1). Grasp open end of snapvent and gently
squeeze it into an elliptical shape. (6). Remove latch block from door.
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Revision 25 521000
MAINTENANCE MANUAL
(7). Lubricate moving parts of latch block B. Cam Lock Installation

(Ref. Automatic Latch Block Assembly
Repair). NOTE: Currently available cam lock is longer
than early cam lock and requires a spacer
B. Automatic Latch Block Installation between lock flange and outside surface of
door skin.
(1). Reconnect link and connector rod end to
handle arm with cotter pin and washer. (1). Position lock boss, torsion spring,
washer and replacement handle into
NOTE: Cotter pin and washer are to be in- position and insert spindle.
stalled on outboard side of connector rod end
to eliminate possibility of interference. To (2). Install spindle washers and screw to
eliminate excess play, use extra washers for secure spindle in lock plate.
shimming.
(3). Attach one spring hook in hole of lock
boss and attach other spring hook at
(2). Secure latch block to lock plate with
notch in lock plate. Use wire to pull
four screws and washers.
spring hook into place.
(3). Check door latching and safelocking (4). Install outside handle.
operation and make any necessary
adjustment. (5). Check door latching and safelocking
operation and make any necessary
11. Cam Lock Replacement adjustment.
(Ref. Figure 202) 12. Latch Assembly or Striker Adjustment
A. Cam Lock Removal (Ref. Figure 203)
(1). Remove outside handle.

(2). Remove latch block. Item Nomenclature
(3). Note position of lock boss and handle CM425 Sealing compound
torsion spring to aid at reinstallation.
(1). Adjust latch assemblies and strike as
(4). Hold handle, lock boss and torsion necessary to ensure proper door
spring in position and withdraw latching, safelocking and keylocking
spindle. Then slide handle lock boss functions.
and torsion spring out of lock plate.
(2). After adjustments are made, perform a
(5). Remove handle grip from handle arm final inspection of all latching and
by loosening setscrew and sliding grip locking functions, then install latch
from arm. covers.
NOTE: When lock is set to locked position, be (3). Fill in gaps and fairin area between
sure that cam actuates hinged lock bar. strikes and bumper stripes at each
When lock is in correct position, secure it in position with sealant (CM425).
place by centerpunching surface of lock
plate assembly close to flat on hexagonal A. Door Seal Compression Adjustment
locking nut.
To adjust door seal compression, remove latch
(6). Replace keyoperated cam lock by covers. Move strikes as necessary in their
unscrewing hexagonal nut. slotted mounting holes.
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521000 Revision 25
MAINTENANCE MANUAL
SNAPVENT LATCH COVER SNAPVENT

(TYPICAL)
DOUBLER DOUBLER
STOP
STOP
AUTOMATIC
DOOR LATCH
WINDOW MECHANISM
DOOR SEAL LATCH COVER (TYPICAL) (4

PLACES)
AUTOMATIC
DOOR SEAL PASSENGER/CARGO DOOR
DOOR LATCH
(369D/E/FF 500N)
MECHANISM
CONNECTOR
CLEVIS ROD
DOOR PANEL
PILOTS DOOR (369D/E/ LATCH SLIDER

FF 500/600N)
ROD MOUNTING LATCH BLOCK
BRACKET
STRIKER
ASSEMBLY
LATCH BLOCK
NOTE 2 SPACER MOUNTING
BRACKET
SHIM WASHER SPRING
(NOTE 3)
CLEVIS
DOOR PANEL (NOTE 1)
(NOTE 2) LATCH SLIDER DOOR
FRAME
LOCKPLATE ASSEMBLY LATCH BLOCK ASSEMBLY
(NOTE 4)
SPRING HOOK NOTCH SPRING CONNECTOR ROD
CLEVIS
SPINDLE LINK PIN
SHIM LINK
LATCH BLOCK ASSEMBLY
ARM
GRIP
NOTES:
1. FOR ADJUSTMENT INFORMATION, REFER TO
ADJUSTING LATCH COMPRESSION.
ESCUTCHEON 2. INSTALL OUTBOARD TO ELIMINATE POSSIBILITY
SET SCREW
LOCK BOSS OF INTERFERENCE.
SPRING PIN 3. AS REQUIRED, FOR LATCH ADJUSTMENT, NOT
CONNECTOR ON ALL WINDOWS.
SPACER 4. IDENTIFIED AS NUTPLATE AT OTHER LOCATIONS.
(NOTE 5) ROD END
CAM LOCK 5. SPACER REQUIRED ON NEW LOCKS WHICH ARE
(KEY OPERATED) LATCH ASSEMBLY EXPLODED VIEW LONGER THAN EARLY MODEL CAM LOCKS.
EARLY SYSTEM
G5210021
Figure 202. Door Latching System Installation (Sheet 1 of 2)
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Revision 25 521000
MAINTENANCE MANUAL
CORNER CRANK
ASSEMBLY
PUSH/PULLROD ATTACHMENT
(TYP)
LATCH COVERS
(6 PL)
NOTE 6
LATCH COVERS
(8 PL)
LATCH BLOCK ATTACHMENT

(TYP)
NOTES: (CONT.)
6. SHIM AS REQUIRED (MAX. 2 WASHERS AT EACH RIVET
LOCATION) BETWEEN DOOR STRUCTURE AND CORNER
CRANK ASSY. MAXIMUM GAP AT RIVET NOT TO EXCEED. G5210022
Figure 202. Door Latching System Installation (Sheet 2 of 2)
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521000 Revision 25
MAINTENANCE MANUAL
B. Engagement Depth of Latch Bolts with modifying as required to compress

Striker Adjustment spring 0.060 0.080 inch (1.524 2.032
mm) when mechanism is at safelocked
Adjust engagement depth of latch bolts with position.
strikes by removing latch covers and moving
latch assemblies as necessary in their slotted (2). Fill gaps and fairin area between latch
mounting holes or by adding shims under strikes and bumper strips at each
strikes. position, using sealant (CM425).
NOTE: Complete safelocking exists when latch 13. Latching Mechanism Operational Check
bolt extension is at maximum and roller on (Early System)
safelock trigger is engaged in safelock slot in
latch slider. At this condition, safelock trig- (1). Check inside and outside door handle at
ger retracts when latch slider is moved all positions for function.
slightly in unlatch direction.
(2). Close door from inside. Entire beveled
C. Connector Rod Adjustment face of each bolt must make contact
(1). Open door or remove from helicopter. with strike and must hold door firmly
against door seals. Bolts must be
(2). Remove latch cover. positioned on strike such that there is
sufficient space for bolt to extend an
(3). Press all safelock triggers and rotate additional minimum 0.125 inch (3.175
handle to safelock position. Remove mm) into strike for safelocking latches
clevis pin from connector rod or latch (Ref. Figure 203).
being adjusted.
(3). Check that each latch bolt makes
(4). Move latch slider manually to complete
contact with mating strike. Unequal
safelock position. Adjust connector rod
striking and latching indicates latch
length so that clevis pin can be in-
assembly or strike require adjustment
stalled easily.
or shimming.
NOTE: Position of fourth and first latches can
be individually adjusted without disturbing (4). Safelock door and observe that door is
adjustment of other latches. If position of forced inward for seal compression at
second or third latches is adjusted, then all each latch position. Unequal safelock-
should be checked. When adjusting all four, ing may indicate that connector rods
start with third latch, and proceed to sec- are not properly adjusted for complete
ond, first and then fourth. extension of latch bolts.
D. Latch Compression Adjustment (Early 14. HookLatch Door Latching System

System) Operational Check
Latch compression spring adjustment may be (Ref. Figure 203)
necessary and should be checked if part
replacement, particularly in stackup between Perform following operational check of
upper clevis on third latch and first mounting hooklatch doorlatching system. If malfunc-
bracket or change in position of clevis has been tion is noted, refer to Table 201 for trouble-
made. shooting and repair information.
(1). Check inside and outside door handle at
Consumable Materials all positions for function. From open
(Ref. Section 910000) and lock positions door handle should
Item Nomenclature spring back to rest position when
CM425 Sealing compound released.
(2). Move handle to open position. Ensure
(1). Readjust spring load using shorter or all four latch hooks are fully extended
longer spring compressor spacer and by from their latch blocks.
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MAINTENANCE MANUAL
INSIDE HANDLE UNLATCH

ACTION POSITION
OUTSIDE HANDLE SAFELOCK

ACTION POSITION
INSIDE HANDLE
TUBING
OUTSIDE HANDLE
SAFELOCKED POSITION
INSIDE HANDLE LATCHED OUTSIDE HANDLE

REST POSITION (NOTE 2) DOOR FRAME STRUCTURE
CHANNEL STRIP LATCH COVER
OUTSIDE HANDLE LATCHED

REST POSITION (NOTE 2)
INSIDE HANDLE DOOR PANEL

SAFELOCKED POSITION
OUTSIDE HANDLE UNLATCH

ACTION POSITION
HANDLE POSITIONS
SAFELOCK AC- (RIGHT DOOR INSIDE VIEW)
TION
LATCH SLIDER DOOR FRAME
CLEVIS
BUMPER
SAFELOCK SLOT
SHIM
SAFELOCK TRIGGER
SAFELOCK ROLLER
LATCH BOLT
LATCH BOLT
ROLLER STRIKER PLATE
INSIDE 0.88 INCH (22.35 MM)
HANDLE UNLATCH ACTION
NOTE 1 NOTES:
1. WHEN LATCH IS COMPLETELY SAFELOCKED,
MINIMUM OF 0.125 INCH (3.175 MM) OF FLAT
SURFACE (BEYOND ANGLED LEADING EDGE )
OF LATCH BOLT MUST BE ENGAGED WITH
LATCH ENGAGEMENT STRIKER PLATE.
(THIRD LATCH INTERIOR 2. LATCHED REST POSITION APPLIES WITH DOOR
SHOWN FOR CLARITY) OPEN OR CLOSED.
G5210031
Figure 203. Door Handle Positions and Latch Engagement (Sheet 1 of 3)
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521000 Revision 25
MAINTENANCE MANUAL
AFT DOOR ASSY

MID DOOR ASSY
WINDOW SEAL
VIEW LOOKING DOWN
DOOR
DOOR FRAME
LATCH BLOCK ENGAGEMENT

(TYP)
G5210032
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Revision 25 521000
MAINTENANCE MANUAL
WITNESS HOLE
PIN
LATCH BLOCK LATCH

SLIDER LATCH
ASSEMBLY
HOUSING
0.050 INCH (1.27 MM) MAX
GAP BETWEEN DOOR
STRIKER PIN AND HOOK
LATCH WHEN DOOR
LATCH CLOSED AND LATCH IN
SLIDER REST POSITION.
G5210033A

(3). Check latch blocks, latch sliders, door that semicircle cutout on latch slider is
waffle and striker pin assemblies for fully seated around pin on latch block.
any nicks, dents, scratches, chipped
paint or other evidence of contact (7). Move handle to open. Note that all four
caused by misalignment of door latches latch hooks extend fully from their
or striker pin assemblies. latch blocks and fully disengage their
striker pins, allowing the door to open.
Handle should spring back to rest
NOTE: Extreme temperatures may cause door
position when released.
seal to swell or door sealtodoor frame
bonding failure. Door seal protrusions 15. Autolatching Pilot and Cargo Doors
caused by swelling or bonding failure may Operational Check
interfere with latching function.
NOTE: When opening door, apply light inward
(4). Check door seal and repair as required. force on door. This reduces wear of latching
mechanism by overcoming door seal pres-
(5). Close door firmly from inside helicopter. sure.
Check that all four latch hooks engage
(1). Open and close door to check for smooth
their striker pins and that there is not
operation of handles and latch mecha-
more than 0.050 inch (1.27 mm)
nism. Check operation of door stop.
between each hook and striker pin.
(2). Close door from inside. Check all inside
(6). Move handle to lock (full down). With latches for correct engagement at latch
door locked, use flashlight to check and safelock positions of interior and
witness hole on each latch block. Note exterior handle. (Ref. Figure 203).
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521000 Revision 25
MAINTENANCE MANUAL
(3). Check that setting interior and exterior

handles to safelock position pulls door Consumable Materials
inward for proper closure and sealing. (Ref. Section 910000)
Item Nomenclature
(4). Check that key locks and unlocks door CM219 Methylethylketone
handle.
16. DoorLatching Mechanism Inspection (All
Systems) 18. Window Replacement
(Ref. Figure 202 and Figure 203) A. Early Style Window Replacement
Make following checks with magnification (Ref. Figure 205) For repair of plastics refer to
glass and strong light: FAA AC 43.131A. Replace window as follows:
(1). All parts for excessive wear, nicks,
cracks and corrosion. Consumable Materials
(2). Threaded parts for worn, crossed or Item Nomenclature
otherwise damaged threads. CM415 Cement
(3). Early latch block assemblies for broken CM418 Cement, epoxy
springs and wear on strike contact CM425 Sealing compound
surfaces of latching bolts; and for undue CM432 Dichloromethane
wear of latch sliders, bolts and bolt CM433 Ethylene chloride
rollers. Current latch block assemblies CM717 Tape, pressure sensitive
for wear, damage or distortion of latch
sliders and latch hook.
(1). Remove snapvent from window (Ref.
(4). Cam lock for jamming when key is Snapvent Replacement).
operated.
(2). Drill out rivets attaching window
(5). Link for wear or distortion. retainers to door structure and remove
window. Remove two screws, washers
(6). Handles for distortion, worn pivot holes
and nuts from door hinge doubler.
and worn finish.
(3). If door frame or window is to be reused,
(7). Escutcheon and handle for looseness, carefully scrape off sealant around edge
distortion, thread damage and break- of door or window frame using a
age. wooden, plastic or other suitable
(8). Lockplate assembly for wear, distortion, nonmetallic scraper.
thread damage and breakage. (4). Repair retainertowindow bond, if
applicable, with dichloromethane
(9). Latch block nutplates for thread
(CM432) or ethylene chloride (CM433);
damage and loose rivets.
or use PS18 or S147 cement (CM415).
(10). Rods and clevis for wear in clevis pin (5). Trim retainer as required to provide
holes, thread damage, and distortion. clearance for door handle and end butt
joint.
17. AntiChafing Tape on Door Frame Repair
(6). Place window in position and check for
(Ref. Figure 208) Inspect condition of anti 0.380 inch (9.652 mm) minimum
chafing tape installed on pilots and cargo engagement and flush fit with window
compartment door frames. For minor repair, frame. Trim excess if required.
remove defective tape where necessary. Clean
frame surface with MEK (CM219). Replace (7). Use 1/2 inch (12.70 mm) pressuresen-
with polyurethane pressuresensitive tape sitive tape (CM717) on edge of window.
(CM717). Bond seals to retainer and to door
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Revision 36 521000
MAINTENANCE MANUAL
frame using cement, epoxy (CM418); (6). Apply 0.250 inch (6.35 mm) tape
bond inside of seals to window using around outside of drawn line.
sealant (CM425). Do not stretch seals
when bonding. (7). Trim glass to the outside of applied
0.250 inch (6.35 mm) tape.
(8). With retainer and window in position
on door frame, press down firmly and (8). Remove tape and gently smooth the
evenly on retainer so that seals are edges.
compressed tightly against window NOTE:
around full circumference of door
D It is best to have ends of seal on aft side of
frame.
window to help keep moisture out while
(9). Locate existing holes in doorreinforc- in flight.
ing frame. Mark and drill holes in D Ensure seal is firmly worked onto door to
retainer. It is permissible to install new prevent seal from being cut too short.
rivets between existing holes in rivet
pattern. (9). Install window seal around periphery of
window opening with groove for glass to
(10). Rivet window to door using rivets of the inside. Cut seal to size if new.
correct length. Blind rivets are used for
retainers riveted to door reinforcing (10). Gently trim seal, where needed, around
frame. top door hinges.
Do not use any tools with sharp
(11). Install doubler over retainer at hinge CAUTION edges to aid in installing glass
area with two screws, washers and
nuts. Drill (No. 21 drill) and ream to into seal, glass is easily damaged.
0.166 inch (4.216 mm) diameter window NOTE: To aid in installation of glass into seal,
panel for screws, using slow speed drill use a mild mixture of soapy water liberally
(700800 rpm). applied to the edge of the glass and into
groove in seal. Do not use any lubricants.
(12). Install snapvent (Ref. Snapvent
Replacement). (11). Install glass from inside by sliding up
into the seal.
(13). Remove protective covering and clean
window (Ref. Sec. 202000). (12). With hands on either side of glass, work
glass firmly into seal.
B. Current Style Window Replacement
(13). Using a blunt plastic spatula or probe,
(Ref. Figure 206) gradually work edge of window into
(1). Using a blunt plastic spatula or probe, groove of window seal.
pull back edge of window seal and (14). If there is a gap at the seal ends, use
gradually work window out from groove commercially available clear silicone
in seal. seal to fill gap.
(2). Remove seal and clean for reinstalla- 19. Hinge Replacement
tion of window, discard if not pliable.
(Ref. Figure 204)
(3). Mask around new glass for marking.
(1). Remove door and drill out hingeat-
(4). Place new glass against door and center taching rivets.
over the window opening.
(2). Install replacement hinges at body
(5). Trace line on glass from window attach points with door hinge pins.
opening in door.
(3). With damaged hinges removed, install
NOTE: The following step is to ensure the glass doors in closed position. Have an
is larger than the door opening so glass will assistant retain door in place by
not blow out in flight. actuating door handle locking levers.
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521000 Revision 36
MAINTENANCE MANUAL
(4). If required for door fit, use onepiece (3). Replace preload spring; with longest
solid aluminum alloy shim, up to 0.040 flat area outboard and aft in hinge body
inch (1.016 mm) maximum thickness recess.
trimmed flush with hinge outer edges,
under upper or lower hinge (between (4). Replace door spring; with longest flat
hinge and door exterior). area also outboard and aft in body
hinge recess.
(5). Mark hinge rivet attach locations
through existing holes in door. Locate NOTE: Forward curved area of door hinge pres-
and mark blind rivet attach points ses against preload spring inboard curved
(cargo door only). area, at installed position.
(6). Remove door hinges and check for (5). Install hinge pins and cotter pins. Pins
proper edge distance. may be installed upward if interference
(7). Drill holes with a No. 28 drill at pilots does not permit installation with cotter
door upper and lower hinge aft attach pin hole down.
points. Use a No. 21 drill at all other
(6). Cover exposed sharp edges of cotter
pilot and cargo door attach points.
pins and pins with sealer (CM424).
(8). On pilots door upper hinge, install
rivets with washers under bucked (7). Install doors and perform operational
heads. check (Ref. Automatic Latching Mecha-
nism (Early System) Operational
(9). Install rivets at remaining pilots door Check.
attach points.
SHIM AS REQUIRED
(10). Install two mechanicallyexpanding (NOTE)
rivets at aft cargo door hinge attach
points.
(11). Install four rivets at remaining attach
points.
(12). Paint as required.
(13). Install doors and perform an operation-
al check (Ref. Automatic Latching
Mechanism (Early System) Operational
Check).
SHIM AS REQUIRED
A. Preload Spring Replacement (NOTE)
(Ref. Figure 205)
Item Nomenclature
NOTE: The following procedures apply to both

upper and lower hinges.
NOTE: SHIM AS REQUIRED UNDER HINGE WITH ONE PIECE
OF 2024T3 ALUMINUM, 0.050 IN. (1.270 MM) MAXIMUM. TRIM
(1). Remove two cotter pins and clevis pins. TO OUTER PERIPHERY OF HINGE.
G521004
(2). Remove door spring first; then remove
preload spring. Figure 204. Door Hinge Replacement
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Revision 36 521000
MAINTENANCE MANUAL
WINDOW
LATCH COVER
(TYPICAL)
FUSELAGE
DOOR FRAME
DOOR SEAL
DOOR SEAL
DOOR PANEL
PILOTS DOOR CARGO DOOR

(369D/E/FF 500/600N) (369D/E/FF 500N)
CLEVIS PIN FUSELAGE STRUCTURE
HINGE PIN SHIM DOOR HINGE RETAINER

(AS REQUIRED) DOUBLER
(NOTE) RIVET
PRELOAD
PRESSURE
SPRING
SENSITIVE TAPE
DOOR
SPRING
WINDOW HINGE
RUBBER DOOR PANEL
STOP
WINDOW ENGAGEMENT
0.380 INCH (9.652 MM) MINIMUM
WINDOW REPAIR
BUSHING
HINGE REPAIR
NOTE:
FILL GAP WITH SEALANT.
G5210013A
Figure 205. Window and Hinge Repair
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521000 Revision 25
MAINTENANCE MANUAL
SEAL SEAL
0.25 IN.
(6.35 MM)
I
WINDOW N
B
R
D
O
U
T
B DOOR FRAME
R
D
SEAL
NOTE: 600N SHOWN, TYPICAL OF ALL HELICOPTERS.

G5210014
Figure 206. Current Style Window Installation

B. Rubber Stop Replacement
(Ref. Figure 205) Replace rubber door stop if (Ref. Section 910000)
damaged or partially separated. Remove door Item Nomenclature
stops by carefully prying bonded rubber out of
hinge recess. Bond new stop to forward end of CM411 Adhesive, epoxy
hinge recess with adhesive (CM411).
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Revision 36 521000
MAINTENANCE MANUAL
20. Automatic Latch Block Assembly Repair (2). Replace anti-chafing tape if damaged.
(Ref. Figure 201 and Figure 207, Sheet 1 of 2) (3). Install washer (if applicable), shims,
Replace worn or damaged parts as necessary. dam (if applicable), strike pin and
Disassemble only to extent required for secure with screws.
replacement of parts. Perform following steps
as required: 22. Litter Door Inspection (50 Hour)
The following is a procedure for inspecting the
Consumable Materials litter door installation for proper condition and
(Ref. Section 910000) security of the quickrelease fastener assem-
Item Nomenclature blies and the rubber seal (gasket) installed
CM108 Graphite, powdered between the window glass and door frame. The
CM118 Grease
visual inspection is applicable to the PN
369H927331 / 2 bubble window assemblies
CM234 Solvent, drycleaning (or PN 369H927311 / 2 flat window assem-
CM307 Lacquer, acrylic semigloss blies, if installed) in the PN 369H90085 litter
door installation.
(1). Lubricate all moving parts except lock, (1). Remove quickrelease fasteners
with grease (CM118) to prevent securing bubble (or flat) windows to
binding. litter doors.
(2). Lubricate lock with powdered graphite (2). Visually inspect each fastener for
(CM108). condition, and each anchor receptacle in
door structure for condition and
(3). At time of disassembly clean reusable
parts except locks, using soft bristle
brush dipped in solvent (CM234). (a). Replace each fastener if stud is loose
or worn.
(4). Dry parts using clean, lintfree cloth or
dry compressed air at 20 psi maximum. (b). Replace anchor receptacle and/or
rivets as required.
(5). Clean keyoperated cam locks, using
dry compressed air at 20 psi maximum. (3). Visually inspect rubber seal (gasket) on
window assemblies for condition. Seal
(6). Touchup handles with semigloss black must be fully intact; rebond seal to door
acrylic lacquer (CM307). structure as required.
(7). Eliminate binding by lubricating (a). Replace seal if worn, cracked or hard.
moving parts.
(4). Reinstall window assemblies to litter
21. Strike Pin Repair doors using quickrelease fasteners.
(Ref. Figure 207) (5). Check for gaps between window glass,
rubber seal and door structure.
NOTE: The 369 model has three different con-
figurations. Select the configuration that (6). Replace seal and/or use shorter length
pertains to your specific application. studs if any gap is noted.
(1). Remove screws, strike pin, dam (if (7). If seal is extruded, use longer length
applicable), shim and washers (if studs; replace seal if extrusion still
applicable) from door frame. exists.
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MAINTENANCE MANUAL
LATCH HOOK
CONNECTOR ROD
LATCH HOOK
CONNECTOR ROD
CONNECTOR
ROD
CLEVIS
LATCH SLIDE
LATCH BLOCK NOTE

LATCH BLOCK
MOUNTING
BRACKET
STRIKER ASSEMBLY
LATCH
BLOCK
LATCH
HOOK
HANDLE
DOOR FRAME ASSEMBLY
LATCH CONNECTOR
CONNECTOR ROD
BLOCK ROD
CLEVIS
LATCH LATCH
HOOK BLOCK
LATCH BLOCK ASSEMBLY

LATCH
HANDLE HOOK
ASSEMBLY
NOTE:
1. SPRING USED WITH EARLY SYSTEMS ONLY. CURRENT SYSTEM
SOLID ROD USED ON CURRENT SYSTEM. CONFIGURATION
G5210051A
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 1 of 2)
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Revision 36 521000
MAINTENANCE MANUAL
DOOR FRAME
(CARGO DOOR
FRAME SHOWN)
RIVNUT
ANTICHAFING
TAPE
SHIM
SCREW
WASHER
STRIKER
SHIM
SCREW SCREW
DOOR FRAME
STRIKER
PIN
SCREW
RIVNUT
SCREW SHIM
RIVNUT
DOOR FRAME
WASHER
STRIKER PIN
NUTPLATE
WASHER
RIVET
RIVET
NUTPLATE
G5210052A
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 2 of 2)
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521000 Revision 36
MAINTENANCE MANUAL
UPPER LATCHES
3.50 INCH 3.50 INCH (8.89 CM)

(8.89 CM)
8.00 INCH (20.32 CM) BLENDED FROM 0.12 INCH (3.05 MM)
DIMENSION TO EDGE OF DOOR (2 PLACES)
8.00 INCH 0.12 INCH (3.05 MM)

(20.32 CM)
SEAL
A
A
0.12 INCH (3.05 MM)
0.25 INCH (6.35 MM)
8.00 INCH (20.32 CM)

SEAL 0.12 INCH (3.05 MM)
(FLUSH WITH B
EDGE OF DOOR
AT BOTTOM) A
0.35 INCH
B (8.89 MM)
A
0.12 INCH
(3.05 MM)
PILOTS DOOR
(LEFT DOOR SHOWN)
(NOTE 1)
FINGER TYPE SEAL
(NOTE 2, 3) SEAL
SECTION AA
A
DOOR REINFORCING 0.12 INCH
FRAME (3.05 MM) A 0.025 INCH
SEAL (FLUSH WITH CARGO DOOR (6.35 MM)
(NOTE 1)
EDGE OF DOOR AT (LEFT DOOR SHOWN)
BOTTOM)
(NOTE 2, 3)
SECTION BB
(BOTTOM SEAL FINGERS DOWNWARD;

PILOTS DOOR ONLY) NOTES:
1. SEAL NOT TO BE LOCATED ON RADIUS OF
REINFORCED FRAME.
2. SEAL INSTALLED USING ADHESIVE ACCORDING
TO CONTAINER INSTRUCTIONS.
3. SHIM AS REQUIRED UNDER SEAL USING TAPE
BONDED WITH ADHESIVE.
G521000A
Figure 208. Door Seal Repair
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MAINTENANCE MANUAL
23. Pilot and Cargo Door Repair 24. Improved Door Seal Installation
(Ref. Figure 209) The following procedure is for
A. Seal Repair
installation of QGR2178 door seals on the
cargo/passenger doors.
(Ref. Figure 208)
Item Nomenclature CM220 Naphtha aliphatic
CM418 Cement, epoxy CM235 Cleaner
CM322 Primer, Silicone, Red
CM414 Adhesive, cyanoacrylic / Accelerator
(1). Carefully pull or scrape away damaged
CM439 Adhesive
seal.
(2). Restore chemical film protection to any (1). Remove existing door seals using
base metal exposed during cleaning Desoclean 45 (CM235) or naphtha
process (Ref. Sec. 202000). aliphatic (CM220). Ensure that all
surfaces are clean to allow proper
(3). Clean seal contact area on metal and adhesion of new seal material. Allow
rubber seal. surface to airdry a minimum of 15
minutes.
(4). Carefully align and bond seal to
mounting surface with cement, epoxy
NOTE:
(CM418) according to container instruc- D On the 369D/E/FF 500N helicopters,
tions. seals are to be installed around the entire
circumference of the aft doors.
NOTE: Correct seal mounting position results D On the 600N helicopters, seals are to be
in an approximately 0.060 inch (1.52 mm) installed around the entire circumference
interference fit between door seal and bum- of the mid doors. Seals are to the applied
per. to the top, bottom and aft edges of the
aftcabin doors.
B. PartiallySeparated Seal Repair
(2). Prime seal faying surface with red
silicone primer (CM321) and allow to
(Ref. Figure 208)
airdry a minimum of 15 minutes.
(3). Apply a thin uniform coat of adhesive
Consumable Materials (CM439) to faying surface of door and
(Ref. Section 910000) seal. Allow to airdry a minimum of
Item Nomenclature five minutes.
(4). Apply a second thin uniform coat of
CM418 Cement, epoxy adhesive to faying surface of door and
seal. Allow to airdry a minimum of
five minutes.
(1). Clean separated area with naphtha
(CM220) and allow to dry for minimum (5). Test glue with clean knuckle. If adhe-
of 20 minutes. sive does not transfer to knuckle, press
the seal into place.
(2). Apply one uniform brush coat of (6). Butt joints at forward and aft lower
cement, epoxy (CM418) to rubber seal locations.
and mating surface contact area. Allow
to dry for 5 minutes and press mating (7). Maximum gap of 0.030 inch (0.762 mm)
surfaces together. at butt joints.
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521000 Revision 36
MAINTENANCE MANUAL
(8). Miter joints at upper locations. NOTE: Use glue very sparingly to achieve best
bond.
(9). Bond mitered joints with adhesive
(CM414). (10). Trim seal flush with edge of door.
QGR2178 SEAL
SEAL MAY BE LOCATED FROM

EDGE TO INCLINE AS SHOWN
TRIM SEAL FLUSH WITH AND AS REQUIRED TO ENSURE
EDGE OF DOOR. PROPER SEAL OPERATION.
POSITION OF SEAL ALONG HINGE SIDE
TYPICAL SEAL POSITION;

SEAL MAY BE RELOCATED AS REQUIRED TO ACHIEVE
PROPER SEAL BETWEEN DOOR AND JAMB. 88759
Figure 209. Improved Door Seal Installation
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Revision 36 521000
MAINTENANCE MANUAL
Section
524000
Engine Access
Doors
MAINTENANCE MANUAL
ENGINE ACCESS DOORS

1. Engine Access Door General 3. Engine Access Door Inspection
(Ref. Figure 201) Engine access doors have (1). Check door hinges, doorattaching
upper and lower door hinges that allow door fit hardware and latches for looseness,
adjustment. Fore and aft adjustment and fit of cracks and damage.
doors is made possible by slotted holes in
hinges and serrated mating surfaces between (2). Check outside edge of door for security
hinges and doors. Lateral adjustment is of bonding between outer and inner
obtained with laminated shims under door skin. Any separation requires repair.
hinges. Closeddoor alignment is provided by (3). Inspect doors for corrosion, distortion,
springtype retainers on door frames at the breaks or cracks and condition of
lower latch, and two locating pins that engage abrasion strip tape along upper inside
holes in lower fuselage structure. door edge and under retainers.
2. Engine Access Door Replacement (4). For repairs (Ref. Engine Access Doors
Repairs).
A. Engine Access Door Removal
4. Engine Access Door Repair
(1). Release three latches to open access
doors. Index mark hinge, shim and A. Sheet Metal Repair
serrated plate to door structure.
(Ref. CSPSRM6, Structural Repair Manual)
Remove three engine access door hinge
Abrasion strip tape along upper inside door edge
attachment screws with washers.
and on area that mates with retainers must be
Forward screws are attached with nuts
replaced when worn.
and aft screws attach to rivnuts.
B. Abrasion Strip Replacement
(2). For inspection (Ref. Engine Access Door
Inspection).
B. Engine Access Door Installation (Ref. Section 910000)
Item Nomenclature
Consumable Materials CM220 Naphtha aliphatic
(Ref. Section 910000) CM710 Tape, high temperature
Item Nomenclature CM717 Tape, pressure sensitive
(1). Replace worn abrasion strip tape along
upper inside door edge by cleaning
(1). Position door and temporarily install contact area with naphtha (CM220);
shim, serrated plate and attachment allow to airdry a minimum of 30
hardware. minutes. Install 0.50 x 40.0 inch (1.27 x
(2). Align indexing marks on shim, serrated 101.60 cm) strip of polyurethane tape
plate and hinge with those on door and (CM717) to clean, dry surface. Apply
then tighten screws. hand pressure to ensure firm contact
and trim as required.
(3). Close and latch doors and check for
(2). Replace worn abrasion strip on area
firm fit with no deflections.
that mates with retainers by cleaning
(4). Apply sealing compound (CM425) to all retainers with naphtha (CM220).
cotter pins. Install high temperature tape (CM710)
to clean, dry surface. Apply hand
(5). For adjustment (Ref. Engine Access pressure to ensure firm contact. Trim as
Door Adjustment). required.
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524000 Revision 18
MAINTENANCE MANUAL
C. Hinge Replacement (1). Carefully drill out rivets and remove

defective latch hook or catch from
Replace door hinges as follows: engine access door or fuselage structure
Replace defective stops or serrated
Consumable Materials adjustment plates, if required, by
(Ref. Section 910000) drilling out attaching rivets.
Item Nomenclature
(2). Locate existing rivet holes and install
CM318 Primer replacement latch, catch, door stop or
adjustment plate. Secure with replace-
(1). Remove door from fuselage structure ment rivets.
(Ref. Engine Access Door Removal).
(3). Adjust latches as required for proper
(2). Remove nut, washers and hinge pivot tension of latch lever to catch without
screw. deflecting door (Ref. Engine Access
Door Adjustment).
(3). Carefully press out hinge pivot point
spacer and separate hinge halves. (4). Refinish area (except latch lever
Retain two nylon washers. assembly) as required (Ref. Sec.
203000).
(4). Carefully drill out rivets that secure
defective hinge half to fuselage struc- 5. Engine Access Door Adjustment
ture.
(5). Transfer existing hole pattern in Door alignment is provided by means of
fuselage structure to replacement springtype retainers riveted in door frames
fuselage hinge half and drill out holes. adjacent to lower latch.
Install hinge and shim on fuselage
structure and secure with replacement Consumable Materials
rivets. (Ref. Section 910000)
Item Nomenclature
(6). Assemble hinge halves with nylon
washers as shown. Press steel pivot CM702 Lockwire CRES
spacer coated with primer (CM318)
through mating holes. Install pivot (1). Remove lockwire from threaded
screw with washer and nut. (adjustment) end of hooks.
NOTE: Install shims under door hinge to obtain (2). Loosen all hooks until spring type
firm fit without binding at doortofuselage retainers engage in light contact with
contact surfaces when door is closed. Use no door deflection when hooks are
slotted holes in hinge and serrated surfaces latched.
to obtain forward and aft adjustment. When
adjustments are complete, tighten screws (3). Unlatch doors and tighten all hooks
that secure hinge to access door. four to five turns. Check door latching
(7). Refinish repaired area (Ref. Sec. and make additional minor adjust-
203000). ments as required.
D. Catch/Latch Hook Replacement (4). Install lockwire (CM702) in hook

threaded end in a manner to allow
Replace defective catches or latch hooks as latching and unlatching without
follows: interference.
Page 202
Revision 18 524000
MAINTENANCE MANUAL
ABRASION
STRIP TAPE
PLATE
CATCH
ABRASION
STRIP
STOP
HOOK
LEVER
AFT LATCHING
BRACKET
PIN
HOOK
PIN
BRACKET
BRACKET
LOWER BRACKET
INSTALLATION
DOOR HOLDUP HOOK
G5240001
Figure 201. Engine Access Doors (Sheet 1 of 3)
Page 203
524000 Revision 18
MAINTENANCE MANUAL
CATCH
HOOK
LEVER
C30/C47 FAIRING
RETAINER
ABRASION
STRIP
RETAINER
CATCH
LEVER
C20/C20R2 FAIRING
AFT LOWER LOCKING ASSEMBLY
G5240002A
Page 204
Revision 18 524000
MAINTENANCE MANUAL
FUSELAGE STRUCTURE
FORWARD HALF
RIVNUT
SHIM
PLATE
STEEL SPACER
NYLON WASHERS AFT HALF
LOWER HINGE
FUSELAGE STRUCTURE
STEEL SPACER
SHIM
FORWARD HALF
SHIM
PLATE
NYLON WASHERS
AFT HALF
UPPER HINGE
G5240003

524000 Revision 18
MAINTENANCE MANUAL
Section
525000
Miscellaneous
Access Doors
MAINTENANCE MANUAL
MISCELLANEOUS ACCESS DOORS

1. Access and Inspection Provisions (3). Inspect doors for corrosion, distortion,
breaks and cracks.
Any time maintenance work is
CAUTION to be performed near engine air 3. Pilot Compartment Floor Access Doors
and engine cooling air inlets, use care to pre-
vent entry of foreign objects that might later Each of the two pilots compartment floor
be sucked into compressor or cooling air access doors are formed by two hinged panels,
blower. Tape covers of cardboard or other hinged at the forward edge to the pilots
suitable material in place over engine cool- compartment floor.
ing air screens. Covers should not be re-
moved until work is completed and debris is A latch at the rear, secures each door in place.
thoroughly cleaned out of the area. Two stainless steel heel strips are hinged and
held in place over each door by a spring.
Removable access doors and covers are
provided in the helicopter for servicing, NOTE: Remove heel strips for better access.
inspection, removal, installation and adjust- Detach springs from clips on underside of
ment of components. strips. Remove hinge pins attaching forward
ends of strips to natatorium pedal mounting
Locations of access and inspections provisions bracket.
are shown in Figure 201 for 369D/E/FF,
Figure 202 for 500N and Figure 203 for 600N 4. Pilot Compartment Floor Access Door
helicopters. Replacement
Areas, components and items accessible A. Pilot Compartment Floor Access Door
through locations shown in the figures are in Removal
Table 201. Screws are used to secure access
doors in stress areas. (1). Remove floor access doors by releasing
Liquid level sight gages allow inspection of latch at rear of door.
lubricant levels for main transmission, engine (2). Raise and hold up rear of heel strips for
oil tank and tail rotor transmission (369 access to hinge pins at forward end of
D/E/FF) or fan transmission (500/600N). door.
Methods for removal and installation are
(3). Remove hinge pin securing forward
obvious for most doors and covers.
edge of door to pilots compartment floor
For information on access doors and covers and remove door.
that are also used for interior trim, Refer to
Sections 253000 and 254000. B. Pilot Compartment Floor Access Door
Installation
2. General Access Doors Inspection
(1). Position door and secure forward edge
(1). Check door hinges, doorattaching to floor using hinge pin.
hardware and latches for looseness,
cracks and damage. (2). If removed, heel strips are reinstalled
by inserting hinge pins through
(2). Check outside edge of door for security brackets on forward end of strip and
of bonding between outer and inner antitorque pedal mounting bracket
skin. Any separation requires repair, and connecting springs to clips on
refer to Structural Repair Manual. underside of heel strips.
Page 201
525000 Revision 18
MAINTENANCE MANUAL
Table 201. Access and Inspection Provisions Information

Door, Cover or Access Provision Provides Access To
Air inlet forward fairings Main rotor mixer controls, main rotor mast base and supporting
structure.
Collective stick cover Aft end of collective stick and associated electrical wiring.
Wiring cover Electrical wiring at seat structure and auxiliary power receptacle.
Pilots seat cover or inboard collective Underseat controls for engine and flight control systems.
pitch stick cover
Plenum chamber access door (air inlet Interior of engine air inlet aft fairing.
bypass door)
Tail rotor drive shaft access door Tail rotor drive shaft and interior of air inlet forward fairing.
Pilots compartment floor access door Left door battery.

Right door optional avionics equipment and controls linkage.
Aft bulkhead access covers Right side oil tank, oil cooler and oil system drain valve.
Left side components of optional cabin heating installation and main
transmission oil cooler.
Footwell fairing Forward landing gear struts and dampers, controls of engine and flight
control systems and electrical wiring. Outboard windows allow
inspections of forward landing gear dampers.
Control access door (1) Lower end of tunnelrouted flight control rods and other control
components in underseat area.
Fuel vent cover Fuel cells vent system crossover fitting.
Tail rotor control bellcrank access Bellcrank connecting tail rotor control rod to tailboom control rod.
fitting
Boom bolts access covers Bolts that secure tailboom to fuselage aft section, tail rotor drive shaft,
tailboom control rod, and damper for tail rotor drive shaft.
Engine access doors Engine, transmission oil cooler, and components in engine
compartment.
Fuel cell access covers (1) Left door fuel quantity transmitter, fuel shutoff valve, fuel cell cover
(for access to engine starting pump), and left fuel cell.
Right door right fuel cell.
Tail rotor drive access hole (below Forward end of tail rotor drive shaft and limited access to aft end of
engine cooling air inlet screen) main transmission.
Instrument panel lower section front Electrical and avionics wiring at lower forward area of instrument panel.
panel
Page 202
Revision 18 525000
MAINTENANCE MANUAL
Table 201. Access and Inspection Provisions Information

Door, Cover or Access Provision Provides Access To
Instrument panel lower section side Wiring, tubing, fuel shutoff control cable, and antitorque control torque
panels tube.
Right side cover is mounting surface for landing light relay.
Left side cover mounting running time meter.
Cargo hook access cover Mount fitting and electrical connectors for optional cargo hook
installation.
Convenience trim panel and main Sight gage to check main transmission oil level. Chip detectors and
transmission trim panel (Ref. Sec. main transmission drain valve.
2500)
Blower access door Main transmission, air cooler blower, and engineto transmission drive
shaft.
Instrument panel fairings Avionics, gages and electrical wiring.
Engine oil filter access panel Gain access for replacement of engine oil filter. (369FF 600N)
Access Provisions Unique to 500/600N

Air inlet forward fairings Main rotor mixer controls, main rotor mast base and supporting
structure.
Antitorque splitter assembly, forward, intermediate and aft control
tube.
Engine plenum access fairing Inner area of air inlet aft fairing.
Fan inlet screen Fan blades and fan/gearbox access cover.
Fan gearbox access cover Fan gearbox and forward driveshaft.
Driveshaft door Forward driveshaft rear coupling.
Pressure relief screens Fan gearbox oil level sight gauge (L/H side).
Tailboom fairing (1) Tailboom attach bolts.

Antitorque control cable quick disconnect and electrical connectors.
Horizontal stabilizer end plates (1) Vertical stabilator controls and YSAS actuator (R/H side).
Horizontal stabilizer access panel (1) Vertical stabilator controls.
Thruster fairing Rotating thruster attachment.
Access Provisions Unique to 600N

Forward floor access covers Fuel cell components.
Engine air bypass door Interior of engine.
NOTE:
(1) Items are stressed and must be installed prior to helicopter flight.
Page 203
525000 Revision 18
MAINTENANCE MANUAL
# $ TAILBOOM MOUNTING
PLENUM ACCESS BOLTS ACCESS DOORS
COVER
# AIR INLET FOR-

WARD FAIRING
# TAIL ROTOR CONTROL BELL-
CRANK ACCESS COVER
# * ENGINE OIL FILTER

CONTROLS TUNNEL ACCESS DOOR
COVER
# $ TAIL ROTOR DRIVE ACCESS
HOLE (UNDER ENGINE COOLING
AIR INLET SCREEN)
# $ BLOWER ACCESS DOOR
# COLLECTIVE STICK COVER

INSTRUMENT PANEL
FAIRINGLEFT SIDE # TRIM MOTOR AC- # WIRING COVER
CESS PANELS
# INSTRUMENT PANEL LOWER
SECTION SIDE PANEL
PILOTS SEAT COVER
CAUTION:
ITEMS PREFIXED WITH AN ASTERISK ( * ) ARE STRESSED AND MUST BE
INSTALLED PRIOR TO HELICOPTER FLIGHT.
NOTES:
# ITEMS TO BE REMOVED FOR 100HOUR OR ANNUAL INSPECTIONS.
$ ITEMS TO BE REMOVED FOR 300HOUR INSPECTIONS.
G5250001B
Figure 201. Access and Inspection Provisions and Locations (369D/E/FF) (Sheet 1 of 3)
Page 204
Revision 18 525000
MAINTENANCE MANUAL
# FOOTWELL # $ * CONTROLS
FAIRING ACCESS DOOR
INSTRUMENT PANEL
TAIL ROTOR DRIVE FAIRINGRIGHT SIDE
SHAFT ACCESS DOOR
PLENUM CHAMBER AC-

CESS DOOR
# TAIL ROTOR CONTROL

BELLCRANK ACCESS COVER
# INSTRUMENT PANEL
LOWER SECTION SIDE
PANEL

SECTION FRONT PANEL
PILOTS COMPARTMENNT
FOOR ACCESS DOOR
ENGINE ACCESS
DOORS # * FUEL CELL AC-
CESS DOOR
# FOOTWELL FAIRING
# AFT BULKHEAD AC- # AFT BULKHEAD AC-
CESS COVER # FUEL VENT COVER
CESS COVER
# * FUEL CELL AC-
CARGO HOOK COVER (FUSE- CESS DOOR
LAGE UNDERSIDE)
INSTRUMENT PAN-
EL FAIRING

SECTION SIDE PANEL
# INSTRUMENT PANEL LOWER SEC-

TION FRONT PANEL
G5250002A
Page 205
525000 Revision 18
MAINTENANCE MANUAL
# 500MD ELECTRICAL 500MD CIRCUIT

CONSOLE BREAKER PANEL
# PILOTS COLLECTIVE PITCH

STICK COVER ASSEMBLY
500MD ASH RECEIVER AND

FLEXIBLE CLOSURE AS- CIGARETTE LIGHTER PANEL
SEMBLY
INBOARD COLLECTIVE PITCH

SUPPORT TUBE STICK COVER (500MD)
CLAMP
SUPPORT TUBE
ASSEMBLY
LOWER CURTAIN
CURTAIN STOP
UPPER
CURTAIN COTTER PIN
SLIDER
FASTENER FASTENER STUD

BUTTON
EXPLODED VIEW (ROTATED)

G5250003A
Page 206
Revision 18 525000
MAINTENANCE MANUAL
# $ HORIZONTAL STABILIZER
ACCESS PANEL
# $ FAN INLET
SCREEN
# ENGINE PLENUM
ACCESS FAIRING
END PLATE (2 PLACES)
# AIR INLET FOR-

WARD FAIRINGS
# $ TAILBOOM FAIRING
PRESSURE RELIEF
SCREEN (2 PLACES)
# CONTROL # $ BLOWER ACCESS COVER

ACCESS
COVER
# COLLECTIVE STICK COVER
# WIRING COVER
INSTRUMENT PANEL # TRIM MOTOR
FAIRING LEFT SIDE ACCESS PANEL

SECTION SIDE PANEL
CAUTION:
ITEMS PREFIXED WITH AN ASTERISK ( * ) ARE STRESSED AND MUST BE
NOTES:
G5250011B
Figure 202. Access and Inspection Provisions and Locations (500N) (Sheet 1 of 2)
Page 207
525000 Revision 31
MAINTENANCE MANUAL
# FOOTWELL
# $ CONTROLS
FAIRING
ACCESS DOOR
INLET ACCESS PANEL

INSTRUMENT PANEL
FAIRING RIGHT SIDE
ENGINE PLENUM
BYPASS DOOR
# FAN GEARBOX
ACCESS COVER
PRESSURE RE- # INSTRUMENT PANEL L
LIEF SCREEN SECTION SIDE PANEL
# INSTRUMENT PANEL LOW

SECTION FRONT PANEL
# $ TAILBOOM PILOTS COMPARTMENT

FAIRING FLOOR ACCESS DOOR
ENGINE ACCESS
DOORS
# * FUEL CELL
ACCESS COVER
# FOOTWELL FAIRING
# AFT BULKHEAD
ACCESS COVER # * FUEL CELL # FUEL VENT COVER
# AFT BULKHEAD
ACCESS COVER ACCESS COVER
CARGO HOOK COVER (FU-
SELAGE UNDERSIDE)
Figure 202. Access and Inspection Provisions and Locations (500N) (Sheet 2 of 2)
Page 208
Revision 18 525000
MAINTENANCE MANUAL
# CONTROL AC-
CESS COVER
# COLLECTIVE
STICK COVER
# WIRING COVER
ACCESS PANEL
INSTRUMENT PANEL
FAIRINGLEFT SIDE
# INSTRUMENT PAN-
EL LOWER SECTION # $ TRIM MOTOR # $ FAN INLET SCREEN
SIDE PANEL ACCESS PANEL # ENGINE PLENUM
ACCESS FAIRING
BYPASS DOOR ASSY END PLATE (2 PL)
# $ TAILBOOM FAIRING
# $ CONTROLS FAIRING PRESSURE RELIEF

SCREEN (2 PL)
# * ENGINE OIL FILTER
ACCESS DOOR
# $ BLOWER ACCESS COVER
* FUEL CELL AC-

CESS COVER INSTRUMENT PANEL
FAIRINGRIGHT SIDE
# $ CONTROLS
# FOOTWELL ACCESS DOOR
PILOTS COMPARTMENT FAIRING
FLOOR ACCESS DOOR
# FAN GEARBOX
ACCESS COVER
# FOOTWELL
FAIRING
CAUTION: # FUEL VENT

ITEMS PREFIXED WITH AN ASTERISK ( * ) ARE STRESSED AND MUST BE COVER
# AFT BULKHEAD
NOTES:
ACCESS COVER
6G52096
Figure 203. Access and Inspection Provisions and Locations (600N)
Page 209
525000 Revision 18
MAINTENANCE MANUAL
FLOOR ACCESS COVERS

(4 PL)
BYPASS DOOR ASSY
6G52089A
Figure 204. Floor Access Covers and Engine Bypass Door (600N)
Page 210
Revision 18 525000
MAINTENANCE MANUAL
Chapter
53
Fuselage
MAINTENANCE MANUAL
TABLE OF CONTENTS
530000 Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fuselage General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Stressed Sheet Metal Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Stressed Sheet Metal Panel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. NonStressed Sheet Metal Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Negligible Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Negligible Damage Inspection Fuselage . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Fuselage Major Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fuselage Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
531000 Windshields and Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Windshields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Aft Section Windows Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Aft Section Windows Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Aft Section Windows Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Windshield Frame Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. NewStyle Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Windshield Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7. Water Leak Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Geon Strips Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Negligible Damage of Canopy/Windshield . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. (Round Nose) Windshields and Aft Section Windows . . . . . . . . . . . . . 203
Figure 202. (Extended Nose) Windshield and Aft Section Windows . . . . . . . . . . . 204
Figure 203. Windshield Installation (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. (Extended Nose) Windshields and Aft Section Windows
(New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
532000 Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Lower Center Fuselage General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Lower Center Fuselage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fuel Tank Support Skin Inspection (Fuel Cells Removed) . . . . . . . . . . . . . . . . . . . . . 201
4. Fuel Tank Support Skins Repair (Fuel Cells Removed) . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Lower Center Fuselage (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . 202
Page i
MAINTENANCE MANUAL

Figure 202. Lower Center Fuselage (Model 600N) . . . . . . . . . . . . . . . . . . . . . . . . . . 203
533000 Upper Aft Section Fuselage (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Upper Firewall Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Firewall and Plenum Chamber Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Soundproofing Insulation Firewall and Plenum Chamber
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Mast Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Mast Support Structure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Firewalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Firewalls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Firewall and Aft Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Firewall, Station 124.00 Insulation and Soundproofing . . . . . . . . . . . . . . . . . . . . . 205
5. Firewall and Plenum Chamber Soundproofing Panel Inspection . . . . . . . . . . . . . . . 205
A. Engine Air Inlet Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Engine Air Inlet (Plenum Chamber) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Upper Aft Section General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Aft Fuselage Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Aft Fuselage Fittings General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Aft Section Strut Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Silver Brazing Procedure Upper Firewall Shell Patch . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Major Bulkheads and Structural Members Aft Fuselage . . . . . . . 207
9. Plenum Chamber Hole Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10. Forward Fuselage Section Structure Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11. Transmission Compartment Air Baffle, Seal and Cover Initial Installation . . . . . . 209
Figure 204. Forward Fuselage Section Structure Rework . . . . . . . . . . . . . . . . . . . 211
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
533030 Upper Aft Section Fuselage (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine/AntiTorque Air Inlet Fan Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Air and Fan Inlet (Plenum Chamber Area) Inspection . . . . . . . . . . . . . . . . . 201
Figure 201. Upper Aft Section (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Upper Aft Section Fuselage (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Upper Aft Section General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Upper Fuselage Controls Fairing (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page ii
MAINTENANCE MANUAL

4. Upper Fuselage Controls Fairing Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Upper Fuselage Controls Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Upper Fuselage Controls Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Engine Inlet Fairings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Engine Inlet Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Engine Inlet Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6. AntiTorque Fan Air Inlet Screen Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Fan Air Inlet Screen Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Fan Air Inlet Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7. Fan Hub and Transmission Cover Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . 204
A. Fan Hub and Transmission Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Fan Hub and Transmission Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8. Engine Plenum Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Engine Plenum Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Engine Plenum Access Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9. Tailboom Attach Fitting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Tailboom Attach Fitting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10. Lower Longeron Inspection (L158, R158) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
11. Forward Upper Longeron Inspection (L137, R137) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Inspection Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
12. Control Tunnel (FS 78.50) Beam Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 205. Control Tunnel (FS 78.50) Beam Inspection . . . . . . . . . . . . . . . . . . . . 209
534000 Tailboom (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tailboom General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tailboom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tailboom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tailboom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tailboom Assembly and Tailboom Extension . . . . . . . . . . . . . . . . . . . . 202
3. Tailboom Extension Replacement (369FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Tailboom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Tailboom Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Tailboom Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
534030 Tailboom (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tailboom Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page iii
MAINTENANCE MANUAL

2. Tailboom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tailboom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tailboom Assembly (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Tailboom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3. Tailboom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Tailboom Flap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Tailboom Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Stator Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Rotating Thruster Cone Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Rotating Thruster Cone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Rotating Thruster Cone Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Rotating Thruster Cone Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9. Stationary Thruster Cone Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Stationary Thruster Cone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Stationary Thruster Cone Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10. Stationary Thruster Cone Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11. Conduit and Support Strap Rebonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Conduit and Support Strap Rebonding . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Horizontal Stabilizer Mount Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
13. 500N35005 Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 204. 500N35005 Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
14. Tail Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
A. Tail Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Tail Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 205. Tail Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
535010 Stabilizer (TTail) (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Stabilizer General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Stabilizer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Horizontal Stabilizer and Tip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Horizontal Stabilizer and Tip Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Horizontal Stabilizer and Tip Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Vertical Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Page iv
MAINTENANCE MANUAL

A. Vertical Stabilizer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Vertical Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Horizontal Stabilizer and Tip Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Vertical Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Stabilizer TTail Removal and Installation . . . . . . . . . . . . . . . . . . . . . 203
6. Horizontal Stabilizer and Tip Plate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7. Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8. Angle of Incidence Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Table 201. Horizontal Stabilizer Angle of Incidence . . . . . . . . . . . . . . . . . . . . . . . . . 204
9. Angle of Incidence Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10. Horizontal Stabilizer Tab Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Table 202. Troubleshooting Tailboom and Tail Surfaces . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Horizontal Stabilizer Incidence Angle Measuring Tool . . . . . . . . . . . 206
Figure 203. Establishing Horizontal Stabilizer Angle of Incidence . . . . . . . . . . . . 206
Figure 204. Sealing Vertical Stabilizer (0003D 0286D) . . . . . . . . . . . . . . . . . . 207
535030 Stabilizer (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Stabilizers Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Horizontal Stabilizer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Vertical Stabilizers Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Vertical Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Vertical Upper and Lower Stabilizer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Vertical Upper and Lower Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Horizontal Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Horizontal Stabilizer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Horizontal Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Stabilizer Installation with YSAS (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 203
4. Horizontal Stabilizer Eye Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Horizontal Stabilizer Eye Bolt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Horizontal Stabilizer Eye Bolt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Replacement . . . . . . . . 205
A. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Removal . . . . . . . . . . 205
B. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Installation . . . . . . . 205
6. Vertical Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8. Horizontal Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9. Vertical Stabilizer Torque Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page v
MAINTENANCE MANUAL

A. Vertical Stabilizer Torque Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Vertical Stabilizer Torque Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 202. Stabilizer Installation without YSAS . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Vertical Stabilizer Installation with Expandable Bolts . . . . . . . . . . . 208
10. Horizontal Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
11. Vertical Stabilizer Torque Tube and/or Bushing Replacement
(NonBonded Bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Vertical Stabilizer Torque Tube and/or Bushing Replacement
(Bonded Bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
13. Vertical Stabilizer Torque Tube Bushing Rework
(NonBonded Bushings to Bonded Bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
14. Vertical Stabilizer Torque Tube Bearing Race Replacement . . . . . . . . . . . . . . . . . . . . 211
15. Stabilizer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Table 201. Troubleshooting Tailboom and Tail Surfaces . . . . . . . . . . . . . . . . . . . . . 212
Page vi
MAINTENANCE MANUAL
Section
530000
Fuselage
MAINTENANCE MANUAL
FUSELAGE
1. Fuselage General webs. The mosthighlystressed skin sections
are those that form the cylindricallytapered
(Ref. Figure 201) The helicopter fuselage tailboom assembly (Ref. Sec. 5340).
consists of three major structural sections; the
forward, lower and aft fuselage sections. For NOTE: No damage can be considered negligi-
classification and definition of types of ble. All damage shall be repaired upon de-
negligible damage, and for guidelines defining tection.
extent of damage requiring repair or replace-
ment, (Ref. Stressed Sheet Metal Panels, 3. Stressed Sheet Metal Panel Inspection
NonStressed Sheet Metal Panels and
Table 201). Cracks, tears or punctures in stressed sheet
metal panels that do not exceed 0.20 inch (5.08
(Ref. Figure 202) The fuselage of the 600N mm) diameter and can be removed by drilling
helicopter is a stretched version of the 500N out with 1/4 inch (6.35 mm) or smaller
Series helicopter with numerous upgrades and diameter drill do not require structural
improvements. (shaded areas indicate new doublers. If cracks, tears or punctures exceed
sections to fuselage) The longer cabin area of 0.20 inch (5.08 mm) diameter, they are to be
the 600N greatly increases passenger and/or repaired or the panel must be replaced per
cargo carrying capacity. Upper deck area instructions in the FAA AC 43.131A & 2A
fairings and covers were added or modified to and Structural Repair Manual.
accommodate control surfaces or air inlet
passages. 4. NonStressed Sheet Metal Panels
The tailboom on the 600N helicopter is Nonstressed sheet metal members consist
essentially the same as the 500N Series, only primarily of hinged covers and doors, except
longer. The vertical stabilizers or endplates are fuel cell access and controls access doors,
longer than on the 500N model, providing an which are stressed (Ref. Stressed Sheet Metal
increased control surface area. Panels).
An extended passenger step alongside the
passenger/cargo compartment allows for easy 5. Negligible Damage Inspection
entrance and exit through either mid or aft
(Ref. Table 201) Panels damaged in excess of
cabin doors.
negligible damage limits (Ref. Table 201)
2. Stressed Sheet Metal Panels should be repaired, or damaged panel should
be replaced per instructions in FAA AC
Stressed sheet metal panels consist primarily 43.131A & 2A and CSPSRM6 (Structural
of helicopter fuselage skins and bulkhead Repair Manual).
Page 201
530000 Revision 19
MAINTENANCE MANUAL
Table 201. Negligible Damage Inspection Fuselage

Maximum Maximum Length
Area *Damage Depth or Surface Remarks
Stressed sheet No unrepaired damage
metal panels. allowed.
(For tailboom, Ref. Sec.
5340).
Nonstressed sheet Dents. Small dents allowed.**

metal panels.
Scratches/nicks. Minor scratches/nicks

allowed.**
Cracks. Smaller of 0.250 Must be one inch or more

inch (6.35 mm) or from any attachment fitting
onefourth panel and/or panel edge.
width.
Main rotor mast. No unrepaired damage

allowed (Ref. Figure 201)
Firewalls. No unrepaired damage

allowed.
Fuselage fittings. Longitudinal 0.010 inch 15% of fitting After polishing or repair.
scratches, dents, and (0.254 mm) length.
nicks.
Transverse scratches, 0.010 inch 10% of fitting After polishing or repair.
dents, and nicks. (0.254 mm) thickness.
NOTES:
* All damage to fuselage exceeding limits given requires repair or replacement of effected panel or
component.
** Dents, scratches and nicks that penetrate aluminum protective coating (4% of panel thickness with paint or
other surface finishes removed) will allow corrosion of aluminum panel, and should be repaired.
Page 202
Revision 37 530000
MAINTENANCE MANUAL
LOWER FUSELAGE
FORWARD FUSELAGE
AFT FUSELAGE
G530000
Figure 201. Fuselage Major Sections
Page 203
530000 Revision 19
MAINTENANCE MANUAL
VERTICAL
STABILIZERENDPLATE
FAIRINGS AND COVERS S
EXTENDED FUSELAGE
TAILBOOM
EXTENDED PASSENGER STEP
STA
78.50
P. STA P. STA
0.00 30.00
6G53052B
Figure 202. Fuselage Model 600N
Page 204
Revision 20 530000
MAINTENANCE MANUAL
Section
531000
Windshields and Aft
Section Windows
MAINTENANCE MANUAL
WINDSHIELDS AND AFT SECTION WINDOWS

1. Windshields (2). Using a blunt plastic spatula or probe,
gradually work edge of window under
Center and lower windshield panels are flap surface of window seal.
clearest acrylic (Ref. Figure 201 and
Figure 202). Upper windshield panels are (3). Maintain pressure on window until
smokegreytinted cast acrylic. The center entire perimeter of window is under
windshield panels are approximately 0.100 seal.
inch (2.540 mm) thick. (4). Apply an even amount of sealing
compound (CM425) to form a water-
2. Aft Section Windows tight seal around window seal to
fuselage and from window seal to
For repair of plastics, Ref. FAA AC 43.131A. window.
Replace aft section window if it is damaged
beyond practical repair, according to applicable 4. Windshield Frame Replacement
instructions in Structural Repair Manual.
(Ref. Figure 204) On the 600N helicopter the
"Aft Section Windows" refer to the upper mid
Item Nomenclature
section windows located above the mid
passenger/cargo doors. On the 500 Series CM305 Lacquer, acrylic
helicopters this area was referred to as the CM425 Sealing compound
"Aft Section".
For older model helicopters with rivetedin
3. Aft Section Windows Replacement windshields, remove or replace windshield
according to applicable instructions in the
(Ref. Figure 204)
Structural Repair Manual.
A. Aft Section Windows Removal A. NewStyle Windshield Installation
(1). Remove old sealing compound from (1). Install windshields in place and install
around edge of window and window hardware (Ref. Figure 203 and
seal. Figure 204).
(2). Using a blunt plastic spatula or probe, (2). After normal installation of windshield,
pull back flap of window seal and grind two screws flush with nuts (Ref.
gradually work window out from under Figure 203).
flap of seal. (3). Touchup with lacquer (CM305).
(3). Remove seal and clean for reinstalla- (4). Seal all windshield seams with sealing
tion of window. compound (CM425).
5. Windshield Inspection
(Ref. Section 910000) Minor defects or imperfections that do not
Item Nomenclature impair pilots critical visibility, or that obvious-
ly are not signs of impending structural failure
CM425 Sealing compound may be considered as negligible. (For allowable
damage limits, Refer to Table 201.)
B. Aft Section Windows Installation 6. Windshield Repair
(1). Install window seal around periphery of For repair of plastics, Ref. FAA AC 43.131A.
window opening in fuselage. Replace windshields if damage beyond
Page 201
531000 Revision 19
MAINTENANCE MANUAL
practical repair, according to applicable having less than 0.125 inch (3.175 mm)
instructions in Structural Repair Manual. insertion. Replace parts with debonding
areas over 8 inches (20.32 cm) in
7. Water Leak Prevention length.
(2). Mask the geon weatherstrip and

windshield on both sides with tape
(CM722).
Item Nomenclature
CM425 Sealing compound (3). Wipe all faying surfaces with aliphatic
naphtha (CM220) and dry for a mini-
mum of 15 minutes.
If water leakage through geon strips of the
forward canopy occurs, remove any existing (4). For small voids:
sealant using a plastic or other nonmetallic
scraper which will not scratch the canopy (a). Apply adhesive (CM414) to all faying
glass. Apply 0.060 inch (1.524 mm) bead of surfaces using syringe if necessary.
sealant (CM425) along gaps between geon
strips. Apply sealant as directed by sealant (b). Use light pressure to hold the joint
manufacturer. closed for a minimum of 2 minutes.
8. Geon Strips Repair (5). For large voids:
(a). Apply accelerator to the acrylic

transparency and air dry for a
minimum of 2 minutes.
Item Nomenclature
CM220 Naphtha aliphatic (b). Apply adhesive to the geon weather-
CM414 Adhesive, cyanoacrylic / Accelerator strip only.
CM722 Tape, polyethylene
(c). Apply local pressure to insure
complete contact between adherents
Fill voids between geon strips and transparen- and maintain pressure for a mini-
cies as follows: mum of 30 seconds.
(1). Measure the insertion depth of acrylic (d). Remove tape and remove excess
windshield into geon slot, reject parts residue with aliphatic naphtha.
Table 201. Negligible Damage of Canopy/Windshield
Maximum
Maximum Length or
Area Damage Depth Surface Area Remarks
Canopy and Windshield. Nicks 0.010 inch 0.250 inch One per square foot
(0.254 mm) (6.35 mm) only.
Scratches 0.010 inch 5.000 inch

(0.254 mm) (12.7 cm)
Spots or stains If removable by light

polishing.
Panels (not windshields or Punctures 0.200 inch

windows). (5.08 mm) dia
Windshield. Polarization faults Small area near edges.

(distortion)
Page 202
Revision 19 531000
MAINTENANCE MANUAL
Table 201. Negligible Damage of Canopy/Windshield

Maximum
Maximum Length or
Area Damage Depth Surface Area Remarks
Doublers or stiffeners. Delamination No more than one area
within each square foot
of windshield.
Grazing around 0.010 inch
delamination (0.254 mm)
UPPER CANOPY WINDSHIELD

(TWO SECTIONS)
OUTSIDE AIR TEMPERATURE

INDICATOR
FUSELAGE AFT SECTION CENTER CANOPY WINDSHIELD

WINDOWS (BOTH SIDES) (TWO SECTIONS)
(NOTE)
LOWER CANOPY WINDSHIELD

(TWO SECTIONS)
CABIN VENTILATION
NOTE: PANEL (FIBERGLASS)
FUSELAGE AFT SECTION WINDOWS
ARE UNIQUE TO ROUNDNOSE
HELICOPTERS ONLY.
G531000
Figure 201. (Round Nose) Windshields and Aft Section Windows
Page 203
531000 Revision 19
MAINTENANCE MANUAL
UPPER CANOPY WINDSHIELD

(TWO SECTIONS)
CENTER CANOPY WINDSHIELD

(TWO SECTIONS)
OUTSIDE AIR TEMPERATURE

INDICATOR
LOWER CANOPY WINDSHIELD

(TWO SECTIONS)
CABIN VENTILATION PANEL

(FIBERGLASS)
G531001A
Figure 202. (Extended Nose) Windshield and Aft Section Windows
Page 204
Revision 19 531000
MAINTENANCE MANUAL
SCREW SCREW
WINDSHIELD WINDSHIELD
NUT NUT
BEFORE AFTER
CL FUSELAGE 2X ONLY
BL 0.0 (SEE NOTE)
STA 75.24
NOTE:
SCREW LENGTH INTERFERES WITH INSTALLATION
OF AIR DUCT INSIDE COCKPIT.
600n6501010101
6G53087
Figure 203. Windshield Installation (New Style)
Page 205
531000 Revision 19
MAINTENANCE MANUAL
AFT SECTION WINDOW

(RH SIDE IS TYPICAL) WINDOW
WINDSHIELDS
SEALANT
(EXTENDED NOSE)
WINDOW SEAL
SEALANT
MID DOOR
FUSELAGE
LOOKING AFT
SCREW
RETAINER WASHER
SCREW WINDSHIELD
WASHER RETAINER FUSELAGE
RETAINER
WASHER
NUT
WINDSHIELD
WINDOW-TO-STRUCTURE INSTALLATION
WINDSHIELD LOOKING INBD
WASHER
NUT
WINDOW-TO-WINDOW INSTALLATION
LOOKING AFT
600n6501010101
6G53053
Figure 204. (Extended Nose) Windshields and Aft Section Windows (New Style)
Page 206
Revision 19 531000
MAINTENANCE MANUAL
Section
532000
Lower Center
Fuselage
MAINTENANCE MANUAL
LOWER CENTER FUSELAGE

1. Lower Center Fuselage General (4). Perform repair (Ref. Fuel Tank Support
Skins Repair (Fuel Cells Removed)).
(Ref. Figure 201) Lower center fuselage is
those areas below fuselage floor level (WL 3. Fuel Tank Support Skin Inspection (Fuel
13.10) on both sides of the center beam and Cells Removed)
between Sta. 78.50 and Sta. 124.00. (1). Check security of fiberglass skin
attachment to support angles and
(Ref. Figure 202) The Lower Center Fuselage brackets.
for the Model 600N helicopter is similar to that
of the 500 Series helicopters except for the (2). Inspect antiabrasion tape for security
additional stretched or extended fuselage of adhesion over rivet heads, all sharp
IplugI station. The extended lower center edges and lap joints.
fuselage section is located at Sta. 78.50
(designated P. Sta. 0.00 thru 30.00) (Ref. (3). Negligible damage (Ref. Table 201,
Section 060000). Additional floor access 530000).
covers for the fuel cell are also contained
4. Fuel Tank Support Skins Repair (Fuel
within this section of fuselage.
Cells Removed)
2. Lower Center Fuselage Inspection
(1). Ref. FAA AC 43.131A Aircraft Inspec-
Item Nomenclature
tion and Repair and Structural Repair
Manual for standard sheet metal CM711 Tape, pressure sensitive
repair.
(1). Repair fuel tank support skins accord-
(2). Inspect electrical harnesses and wiring ing to applicable instructions in FAA
for frayed insulation and grounding AC 43.131A & 2A or Structural Repair
terminals for corrosion. Manual.
(3). If cargo floor is bent or punctured, (2). Cover exposed rivet heads with 10 mil
remove appropriate fuel cell access by 1 inch (2.54 cm) tape (CM711) to
cover and inspect fuel cell. prevent chafing fuel cell fabric.
Page 201
532000 Revision 19
MAINTENANCE MANUAL
FLOOR WEB
(0.016 IN. (0.4064 MM) CENTER BEAM
2024T3 AL ALY)
STIFFENER
STIFFENERS (0.020 IN. (0.508 MM)
(0.032 IN. (0.8128 MM) 7075T6 AL ALY)
(TYPICAL 8 PLACES) WEB
7075T6 AL ALY) (0.016 IN. (0.4064 MM)
(TYPICAL 7 PLACES) 7075T6 AL ALY)
DOUBLER
STIFFENER (0.032 IN. (0.8128 MM)
(0.032 IN. (0.8128 MM) 7075T6 AL ALY)
7075T6 AL ALY)
STA 119.67 RIB
(0.025 IN. (0.635 MM)
7075T6 AL ALY)
WL 13.10
124.00 LOWER FRAME

(0.020 IN. (0.508 MM)
157 CRES)
STA 113.85 RIB
STIFFENERS (0.025 IN. (0.635 MM)
(0.020 IN. (0.508 MM) 7075T6 AL ALY)
2024T3 AL ALY)
STA 108.04 RIB
DOUBLER (0.025 IN. (0.635 MM)
(0.025 IN. (0.635 MM) 7075T6 AL ALY)
2024T3 AL ALY)
STA 102.23 RIB
WEB (0.025 IN. (0.635 MM)
(0.016 IN. (0.4064 MM) STA 90.61 RIB 7075T6 AL ALY)
2024T3 AL ALY) (0.040 IN. (1.016 MM)
7075T6 AL ALY) JACK FITTING
DOUBLER (PART OF STA 96.42 RIB)
(0.050 IN. (1.270 MM)
7075T6 AL ALY)
DOUBLER STA 96.42 RIB ASSY
STIFFENER CARGO HOOK FITTING (0.050 IN. (1.270 MM)
(0.050 IN. (1.270 MM) (IF APPLICABLE)
(0.032 IN. (0.8128 MM) 7075T6 AL ALY) 7075T6 AL ALY)
7075T6 AL ALY)
STA 84.70 RIB
(0.032 IN. (0.8128 MM)
7075T6 AL ALY)
CANT STA 78.50
LOWER FRAME
(0.040 IN. (1.016 MM)
2024T3 AL ALY)
G532002A
Figure 201. Lower Center Fuselage (369D/E/FF 500N)
Page 202
Revision 19 532000
MAINTENANCE MANUAL
FLOOR ACCESS
COVER, FUEL CELL
CENTER BEAM
P STA
30.00
P STA
0.00 STA 124.00
LOWER FRAME
FLOOR ACCESS
COVER, FUEL CELL
(2 PL)
CANTED STA 78.50

BULKHEAD 600N2500011010
6G53054
Figure 202. Lower Center Fuselage (Model 600N)

532000 Revision 19
MAINTENANCE MANUAL
Section
533000
Upper Aft Section
Fuselage
(369D/E/FF)
MAINTENANCE MANUAL
UPPER AFT SECTION FUSELAGE (369D/E/FF)

1. Upper Firewall Replacement (9). Using solvent (CM234), clean forward
flanges, lower flanges and surface
where tape routing covers fasteners;
Consumable Materials then apply tape (CM721).
Item Nomenclature (10). Install compressor cooling air duct
CM234 Solvent, drycleaning support bracket.
CM721 Tape, aluminum foil (11). Install tailpipes.
2. Firewall and Plenum Chamber Panels

Use care when working on or Replacement
CAUTION around firewall shell because of
its lightweight construction.
(1). Remove tailpipes (Ref. Chap. 78, (Ref. Section 910000)
Exhaust System Replacement). Item Nomenclature
(2). Remove tape covering fasteners and CM419 Sealer
firewall edges.
(3). Detach compressor cooling air duct Replace all defective, torn or fraying sound-
support bracket (Ref. Chap. 71, Engine proofing panels. Loose panels may be pressed
Cooling System Repair and Replace- back in place. (For part number identification
ment). Remove firewall shell by pulling of individual panels, refer to the IPC.)
out button head fasteners (Ref.
Figure 202). (1). Open engine compartment access doors.
(2). Remove individual panels (Ref.
(4). If burn marks are detected on firewall Figure 201, Sheet 1 of 2) by pulling
shell or button head fasteners, inspect away from structure.
airframe above burn marks for damage.
(3). (If applicable) Remove individual
(5). Replace damaged or corroded fasteners. panels (Ref. Figure 201, Sheet 2 of 2) by
removing fasteners.
(6). Replace aft firewall shell if damaged
beyond practical repair. Trim replace- NOTE: Panels have pressuresensitive tape
ment shell to fit installation. Allow backing.
sufficient trim excess for folding back to
provide double thickness at attach (4). Prior to installing replacement panel,
points. clean surfaces with solvent (1, Table
201, 9100).
(7). Pierce fastener holes in new firewall
(5). Install replacement panel in place and
shell to align holes in surrounding
trim edges as necessary. Press panel in
fuselage rings and waterline 34.96 rib.
place to secure.
(8). Place firewall shell in position and (6). Seal edges of replacement panel with
secure in place by pressing fasteners sealer (130).
into holes. Attach compressor cooling
air duct support bracket to hoist fitting (7). Reinstall trim (Ref. Sec. 2530, Interior
(Ref. Chap. 75, Engine Cooling System Trim Replacement) and close engine
Repair and Replacement). access doors.
Page 201
533000 Revision 35
MAINTENANCE MANUAL
3 PANEL
5 PANEL
7 PANEL 39 PANEL
SOUNDPROOFING PANELS
(FIREWALL AND PLENUM
CHAMBER) AFT SECTION AND CANTED
FORWARD FIREWALL
37
29
11
35
33 31
45
43 15 17 18 16
21 23 22
13 19 14
SOUNDPROOFING PANELS 20
(ON AFT SIDE OF ACCESS
DOORS) (NOTE 1)
27 25 28
NOTES:
1. RIGHT PANEL SHOWN. OPPOSITE
SIDE LEFT PANEL (41) IS SAME;
EXCEPT MIRROR IMAGE AND A
SOLID PANEL.
2. ALL DASH NUMBERS SHOWN
APPLY TO BASIC PART NO.
369H2008. (EXAMPLE: 25
INDICATES PART NO. 369H200825.) SOUNDPROOFING PANELS
(ENGINE COMPARTMENT
SIDE OF FIREWALL)
G5330031
Figure 201. Soundproofing Insulation Firewall and Plenum Chamber (Sheet 1 of 2)
Page 202
Revision 19 533000
MAINTENANCE MANUAL
TRANSMISSION
PANEL
CURRENT CONFIGURATION
QUARTER
PANEL
TRANSMISSION
PANEL
EARLY CONFIGURATION
QUARTER
PANEL
G5330032
Figure 201. Soundproofing/Insulation Firewall and Plenum Chamber (Sheet 2 of 2)
Page 203
533000 Revision 19
MAINTENANCE MANUAL
A. Mast Support Structure (7). Clean and inspect any suspected area;
use dyepenetrant to determine if a
The mast support structure is part of the crack does exist. If a crack is found,
fuselage structure and is composed of two part must be replaced.
longitudinal forged fittings, a lower pan and
an aft pan. The mast support structure (8). Inspect mast support structure for
supports and mounts the main rotor mast. corrosion, loose bolts and rivets and
general condition of finish.
NOTE: The main rotor static mast has been re-
moved, in its entirety, from this section be- (9). Check that mast support structure pan
cause of duplicate information in Section drain hole is open.
633000. Refer to Section 633000 for all
information concerning the main rotor stat- (10). Reinstall controls tunnel cover.
ic mast.
(11). Reinstall left and right forward sections
3. Mast Support Structure Inspection of air inlet fairing (Ref. Engine Inlet
Fairing Replacement).
Accomplish the following inspection at
specified intervals (Ref. Chap. 05). (12). Reinstall main gearbox access cover
and trim.
When working near or around
CAUTION engine air and cooling inlets, A. Firewalls
use care to prevent entry of foreign objects
(Ref. Sec. 71). (Ref. Figure 202) A shelllike aft section upper
firewall surrounds the upper portion of engine
(1). Remove left and right sections of air combustion chamber and exhaust pipe
inlet forward fairing (Ref. Engine Inlet assembly. The design contains engine heat as
Fairing Replacement). well as any fire that might develop within the
engine compartment. Upper firewall is thin,
(2). Remove interior trim (Ref. Sec. 2530, 0.0015 inch (0.0381 mm) thick sheet, rigidized
Interior Trim Replacement) and main CRES sheet covered with double thickness of
gearbox access cover (same section). nonflammable ceramic fiber blanket.
(3). Detach control tunnel cover from 4. Firewalls Inspection

structure and slide out of way.
No unrepaired damage is permissible. (For
NOTE: Use bright light and 5power magnify- repairs to forward firewall, Ref. FAA AC
ing glass to carefully inspect areas described 43131A & 2A or Structural Repair Manual.)
in steps below for evidence of cracks. For repairs of the upper firewall (Ref. Silver
Brazing Upper Firewall Shelf Patch).
(4). Inspect visible areas of mast support
fitting, mast base and mast tube, with (1). Inspect forward firewall for punctures
particular attention to base attachment and corrosion.
areas and shaded areas.
(2). Inspect upper firewall for punctures,
(5). Inspect both side of channels on aft corrosion and evidence of contact with
canted bulkhead from mast support discoloration. If contact with discolor-
fitting down to waterline 34.00 with ation is observed on the firewall
particular attention to points of attachment button heads, remove the
attachment. upper firewall and inspect the attach
frames for discoloration or damage;
(6). Inspect side channels and fore and aft contact MDHI for further directions.
webs of controls tunnel, from mast
support fitting down to top of pilots (3). Inspect for complete seal around
seatback (canted bulkhead waterline openings for overrunning clutch, engine
45.36). compressor air inlet and oil cooler.
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Revision 38 533000
MAINTENANCE MANUAL
TAIL ROTOR DRIVE SHAFT FAIRING
REMOVABLE PANEL
CANTED STA. 124.00 WATERLINE 34.96 RIB

CHANNEL
AFT SECTION UPPER FIREWALL

ENGINE AIR INLET (NOTE)
INSTALLATION
(PLENUM CHAMBER)
FORWARD ENGINE ENGINE AIR INLET SIDE PAN

AIR INLET PANEL
DRAIN FITTING
ENGINE AIR
INLET PAN AFT SECTION FORWARD FIREWALL
(NOTE)
369D/E/FF SHOWN
NOTE:
AFT SECTION FIREWALL IS A REMOVABLE ASSEMBLY. BOTTONHEAD FASTENERS
ARE WITHDRAWN FROM INSIDE SURFACE OF FIREWALL SHELL TO REMOVE. G533008A
Figure 202. Firewall and Aft Section
A. Firewall, Station 124.00 Insulation and (4). Check that all individual panels are
Soundproofing securely attached to firewall and
plenum areas with no loose edges.
(Ref. Figure 201, Sheet 1 of 2) Engine compart-
ment forward firewall is insulated and
soundproofed for heat and noise reduction in (5). Check panels in passenger compart-
passenger/cargo compartment. ment of defects, tears, looseness, or
missing panels.
5. Firewall and Plenum Chamber
Soundproofing Panel Inspection (6). For applicable repairs refer to Plenum
Chamber Hole Sealing reference.
(Ref. Figure 201, Sheet 1 of 2 and Figure 202)
(1). Remove trim (Ref. Sec. 253000, A. Engine Air Inlet Fairing
Interior Trim Replacement) for access
to passenger/cargo compartment
firewall areas. Open engine access The engine air inlet fairing on top of the
doors to inspect engine compartment fuselage structure directs ambient outside air
panels. to the engine air inlet and oil cooler blower.
The fairing installation consists of a forward
(2). Check for defective, torn, loose or fairing section and an aft fairing section. Right
missing panels. and left halves of forward fairing are remov-
able. The aft fairing is riveted to fuselage
(3). Inspect aft firewall for security, punc- structure. A UHF/VHF antenna is bonded to
tures and corrosion. the aft vertical face and is part of aft fairing.
Page 205
533000 Revision 38
MAINTENANCE MANUAL
6. Engine Air Inlet (Plenum Chamber) (1). Negligible Damage (Ref. Table 201,
Inspection 530000).
(1). For access, open bypass door on right (2). Replacement. Replace fittings according
side of engine air inlet and engine to Structural Repair Manual.
compartment access doors for view of
rear side of plenum (Ref. Figure 202). 7. Aft Section Strut Repair
Repair of strut is limited to smoothing out
(2). Inspect all panels for evidence of
minor dents, scratches or nicks. Replace strut
corrosion, security of rivets and punc-
if it is badly damaged according to Structural
tures.
Repair Manual.
(3). Inspect engine air shield mounting clips
8. Silver Brazing Procedure Upper Firewall
for secure attachment.
Shell Patch
(4). Inspect aft section strut for rivet (Ref. Figure 203)
corrosion and edge clearance where it
passes through cutout in forward panel.
For applicable repairs (Ref. Aft Section Consumable Materials
Strut Repair). (Ref. Section 910000)
Item Nomenclature
(5). Ensure that removable forward panels CM234 Solvent, drycleaning
are secure. Inspect rubber seals for CM721 Tape, aluminum foil
security and partial compression. CM817 Brazing flux
(6). Inspect drive shaft tube fairing for CM818 Brazing alloy
dents, buckled or wrinkled areas and
signs of corrosion. (1). Remove aft section upper firewall (Ref.
Upper Firewall Replacement).
(7). Close engine compartment access doors
and two air inlet access doors. (2). Remove tape and ceramic fiber blankets
from firewall shell.
A. Upper Aft Section General Repair
(3). Clean firewall shell with stiff bristle
Ref. FAA AC 43.131A & 2A and Structural brush moistened with solvent (CM234)
Repair Manual for additional repair proce- and wipe dry with clean, dry cloth.
dures.
(4). Smooth out rigidized pattern in area on
B. Aft Fuselage Fittings which patch will be brazed.
Mast support structure fitting and fuselage (5). Cut suitable repair patch for Type 321
boom fairing frame fitting are critical fatigue stainless steel sheet in thickness range
loaded parts. Any damage in excess of negligi- of 0.00150.0018 inch (0.03810.04572
ble limits specified in (Ref. Aft Section Strut mm).
Repair) requires replacement of part. (6). Contour patch to match contour of
firewall shell repair area.
C. Aft Fuselage Fittings General Repair
Use only stainless steel wire
Repair of cast and forged fittings should only CAUTION brush in next step. Particles
be temporary and be performed only when from bristles of other metals can contami-
replacement components are not immediately nate the patch area and cause brazing to
available. Replacement of bushings or inserts fail.
that become part of fitting assembly are
considered insertion repairs. (Insertion repairs (7). Use stainless steel wire brush to clean
are described in FAA AC 43.131A & 2A and and abrade inner and outer surfaces of
Structural Repair Manual.) stainless steel patch and firewall.
Page 206
Revision 38 533000
MAINTENANCE MANUAL
STA. 197.78 BOOM FAIRING

CANTED FRAME FITTING
BOOM FAIRING RING
AFT SECTION STRUT
AFT SECTION
UPPER FIREWALL
ENGINE AIR INLET

INSTALLATION
(PLENUM CHAMBER)
G533006
Figure 203. Major Bulkheads and Structural Members Aft Fuselage
(8). Rinse patch and firewall shell thor- Use extreme care not to over-
oughly with clean water and allow to CAUTION heat and burn through firewall
air dry. shell.
(11). Braze patch in place with Class 8 silver

(9). Coat surfaces to be joined with a thin brazing alloy (CM818), using suitable
even coating of silver alloy brazing flux torch to heat patch area to temperature
(CM817). moderately above 1295F (707C) flow
point of brazing alloy.
(10). Use clamp or other suitable device to (12). Allow joint to cool for at least 60
hold patch in place during brazing seconds before removing clamping
operation. device.
Page 207
533000 Revision 38
MAINTENANCE MANUAL
(13). Remove flux by immersing repaired reinforcement at the forward attach points for
area in water at 160212F the engine inlet fairing assemblies.
(72101C) for 40 minutes.
(14). Thoroughly rinse in clear, running Consumable Materials

water; air dry, or wipe dry with clean, (Ref. Section 910000)
dry cloth. Item Nomenclature
CM318 Primer
(15). Install ceramic blanket on outer surface
of firewall shell.
(1). Remove engine inlet forward fairing
(16). Install aft section upper firewall shell assemblies from helicopter (Ref. Engine
(Ref. Upper Firewall Replacement). Inlet Fairing Replacement).
(17). Install tape (CM721) on flanges of (2). Remove interior trim panels and wire
firewall shell. harnesses, as applicable, to gain access
to work area at forward area at forward
attach nutplate assembly for L/H and
9. Plenum Chamber Hole Sealing
R/H engine inlet forward fairings.
(Ref. Figure 203) (3). Remove existing forward nutplate (for
both L/H and R/H fairing assemblies)
Consumable Materials from fuselage frame structure.
Item Nomenclature
(4). Inspect upper fuselage skin for cracks
or damage at area of forward nutplate
CM418 Cement, epoxy attachment holes. Also inspect repair
CM424 Sealing compound doublers if, previously installed, on
CM713 Tape, pressure sensitive upper fuselage skin.
NOTE: If cracking or damage to fuselage skin
All tape must be applied to out- or repair doublers is noted, perform the fol-
CAUTION side of inlet surfaces, so that lowing:
any subsequently loosened tape cannot en-
(a). Stop drill all cracks or remove
ter plenum chamber to cause engine dam-
damaged skin area or damaged
age.
repair doublers prior to rework.
(1). Using 10 mil by 1 inch (2.54 cm) Perform all work in accordance with
pressuresensitive tape (CM713), tape FAA AC 43.131A, Aircraft Inspec-
all 0.130 inch (3.302 mm) diameter or tion and Repair.
larger holes. (b). Field fabricate and install doublers
on outer fuselage skin. Drill
(2). Using sealant (CM424), seal all holes 0.1960.204 inch (4.9785.182 mm)
less than 0.130 inch (3.302 mm) diameter hole in each doubler to
diameter. match existing hole in fuselage skin
for fairing attach screw. Use existing
(3). Rebond loose rubber seals with adhe-
rivet pattern as shown; install
sive (CM418) according to container
MS20470AD3 rivets with primer
instructions.
(CM318).
10. Forward Fuselage Section Structure (c). Prime and paint double to match
Rework finish color of helicopter.
(Ref. Figure 204) The following information is (5). Inspect fuselage frame structure
a procedure for installing support assemblies (channel) for cracks or damage at
to the fuselage frame structure to provide forward nutplate attach areas.
Page 208
Revision 38 533000
MAINTENANCE MANUAL
NOTE: If no cracking or damage to fuselage 11. Transmission Compartment Air Baffle,

frame is noted, install 80369D224003 and Seal and Cover Initial Installation
4 support assemblies at FWD side of frame (Ref. Figure 205) (Serial No. 0003D thru
structure using rivets. Drill holes in support 0333D only)
assemblies for nutplates and for conduit
clearances as required. Install nutplate Consumable Materials
rivets (MS20470AD3) through support, (Ref. Section 910000)
frame, upper skin and doubler, if installed. Item Nomenclature
N/A Calking compound
(6). If cracking or damage to fuselage frame CM712 Tape, pressure sensitive
is noted, perform the following:
(1). Remove engine air inlet forward
fairings.
(a). Stop drill all cracks or remove
(2). Remove cooling fan inlet screen.
damaged area prior to installation of
repair angles and support assem- (3). Remove aft compartment interior trim
blies. Perform all work in accordance panels and blower access door.
with FAA AC 43.131A, Aircraft (4). Install PN 369D2654119 upper baffle
Inspection and Repair. assembly as follows;
(a). Position baffle between main trans-
mission and mast support structure.
(b). Field fabricate and install repair Align four attach holes in baffle with
angles at AFT side of fuselage frame existing holes in structure.
structure (channel) and install (b). Install baffle with screws, washers
80369D224003 and 4 support and nuts. Seal screw heads with
assemblies at FORWARD side of sealant (CM425).
frame structure using MS20470AD3 (5). Install PN 369D26542 lower baffle to
rivets. Drill 0.096 inch (2.4384 mm) upper baffle with two screws and
diameter holes in angles to match washers at matching nutplates in upper
support assemblies. baffle.
(6). Disconnect 5/8 inch (15.875 mm)
diameter drain tube at mast support
(c). Drill holes in support assemblies and base and insert tube though hole in
repair angles for nutplates and for baffle. Safetywire drain tube to struc-
conduit clearance as required. Install ture.
nutplate rivets through support, (7). Reinstall blower access door.
frame, angle, upper skin and doubler, (8). Position and install PN 369D2654311
if installed. and 12 seal assemblies at lower baffle
and blower access door as shown.
Install seal assemblies with screws and
(7). Check installation of 80369D224003 washers at matching clipnuts on lower
and 4 assemblies and repair angles baffle and on blower.
and doublers, if installed, for discrepan- NOTE: If excessive gap, 0.060 inch (1.524 mm)
cies. or more, exists between structure and rub-
ber extrusion on seals, fill gap by bonding
strip of adhesivebacked gasket to struc-
(8). Reinstall removed components. ture.
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533000 Revision 38
MAINTENANCE MANUAL
(9). Position PN 369D2654511 and 21 NOTE: Not applicable if modified rotor brake
cover assemblies as shown; align cover handle trim cover panel has already been in-
attach holes with existing fairing attach stalled.
nutplates. Temporarily secure cover
assemblies with screws and washers, 5 (a). Carefully trim modified trim cover
places each. panel assembly (for LH or RH rotor
brake handle assembly). Locate and
drill screw attach holes in modified
(10). Using caulking compound, seal all gaps panel.
between fuselage structure and baffle;
seal and cover assemblies. (b). Slide modified trim panel boot over
brake handle. Align screw holes and
check panel for fit. Remove panel and
(11). Remove screws securing cover assem-
make minor trim adjustments as
blies. Reinstall engine air inlet forward
required.
fairings.
(c). Install panel if removed and secure
(12). Reinstall aft compartment trim. panel with attaching hardware.
(d). Push panel boot aft on brake handle
(13). For helicopters equipped with Rotor approximately two inches and secure
Brake Kit, perform the following; with fastener tape.
Weight Arm Moment
lbs (kg) inches (cm) inlbs (kgmm)
+1.5 (+0.681) 110.2 (279.908) +169 (+1947.0828)
Page 210
Revision 38 533000
MAINTENANCE MANUAL
DOUBLER (NOTE 1)
0.030 INCH (0.762 MM)
2024T3 AL ALY SHEET
BL
6.00
LH
CANTED
STA 78.50
0.1960.204 INCH
(4.9785.182 MM) HOLE OUTER SKIN
TO MATCH EXISTING
SCREW HOLE
369A24005 ANGLE
STA.
89.39
DOUBLER
3 RIVETS EACH SIDE VIEW 369H2508 FRAME
OF DAMAGE (AD3)
SKIN
NUTPLATE
(NOTE 5) 80369D224003, 4
SUPPORT FORWARD
SIDE OF FRAME
(NOTE 3)
ANGLE 0.020 INCH
SUPPORT (0.508 MM) AFT
(LH SHOWN) ANGLE SIDE OF FRAME
(NOTES 2, 3) FRAME (NOTES 2, 3)
UP
VIEW
INBOARD DOUBLER
SKIN
NOTES: 80369D224003, 4
1. DOUBLER ON OUTER SKIN TO PICK UP EXISTING RIVETS. SUPPORT FORWARD
2. REPAIR ANGLE INSTALLED ONLY IF FRAME DAMAGE IS NOTED. SIDE OF FRAME
3. DRILL HOLES IN SUPPORT/ANGLE AS REQUIRED FOR CONDUIT (NOTE 3)
CLEARANCES. FRAME
4. STOP DRILL ALL CRACKS OR REMOVE DAMAGED AREA.
5. INSTALL NUTPLATE RIVETS THRU SUPPORT, FRAME, ANGLE
(IF INSTALLED), SKIN AND DOUBLER.
6. INSTALL RIVETS WITH PRIMER. VIEW
G533007A
Figure 204. Forward Fuselage Section Structure Rework
Page 211
533000 Revision 38
G5330091
ACCESS DOOR 369D265439 GASET
369D2654315 GASKET
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies (Sheet 1 of 2)
NOTE 1
15 GASKET
MAST SUPPORT STRUCTURE
369D23009 FRAME 369D2654119 BAFFLE 9 GASKET
15 GASKET INSTL.
19 BAFFLE NOTE 6 NOTE 9 19 BAFFLE
CANTED STATION
124.0
NOTE 2
MAINTENANCE MANUAL
NOTE 5
5 COVER NOTE 4
HEATER DUCT
NOTE 2 369D26542 BAFFLE
NOTE 7
15 GASKET
NOTE 4 7 SEAL
3 COVER
13 SEAL NOTE 8
533000
NOTE 9 ACCESS
DOOR
NOTE 3
19 GASKET
NOTE 8
NOTE 3
9 GASKET
369D26542 BAFFLE
369D26542 BAFFLE CL SHIP NOTE 8 CANTED
ACCESS DOOR
21 SEAL ASSEMBLY STATION
VIEW LOOKING FORWARD 11 SEAL ASSEMBLY
124.0
NOTES:
1. MOLD ALONG STRUCTURE AND JOGGLE ON 369D22070 ACCESS DOOR. 4. INSIDE CONTOUR TO MATCH 369D26542 BAFFLE.
2. TRIM REAR END ALONG CANTED STA. 124.0 TO CLEAR STRUCTURAL 5. FORWARD FLANGE TO MATCH 369D26542 BAFFLE.
Revision 38
CSPHMI2
COMPONENTS. CLEARANCE TO STRUCTURE BEFORE BONDING SEAL 6. JOGGLE TO CLEAR 369D26542 BAFFLE.
Page 212
IS 0.16 INCH. 7. OPTIONAL 0.50 INCH WIDTH CUTOUT FOR ROTOR BRAKE (RH CONTROL)
3. MOLD BOTTOM END ALONG UPPER OUTSIDE CONTOUR OF 369D22070 8. HOLE(S) MATCH CLIP NUTS IN 369D22070 ACCESS DOOR.
ACCESS DOOR. TRIM BOTTOM END TO SECURE MINIMUM OVERLAP 9. HOLE(S) MATCH CLIP NUTS IN 369D26542 BAFFLE.
OF 0.50 INCH.
MAINTENANCE MANUAL
369D2654119 BAFFLE SHIP STRUCTURE
B RUBBER
EXTRUSION
369D26543 SEAL
C C
GASKET 369D2654119
GAP (NOTE 3) BAFFLE
NOTE 1
369D2654321 SEAL
NAS6038 SCREW (4)
AN960PD10L WASHER (4)
(LH SHOWN)
B NOTE 2
369D26542 369D2654311 SEAL
BAFFLE (LH SHOWN)
369D22070
ACCESS DOOR 369D22070
ACCESS DOOR
NAS6083 SCREW 369D2654521 COVER
AN960PD10L WASHER (11 OPPOSITE)
369D26542 BAFFLE
369D2654311 SEAL NAS6028 SCREW (2)
369D220253 FAIRING PLATE AN960PD10L WASHER (2)
(NOTE 5)
VIEW BB
NOTE 4
D
369D22025 FAIRING
VIEW DD
(TYPICAL BOTH SIDES)
D 369D2654119 BAFFLE
VIEW CC NAS6038 SCREW (4)
AN960PD10L WASHER (4)
MS21043L3 NUT (4)
NOTES:
1. DURING INSTALLATION OF 369D26542 BAFFLE, DISCONNECT
AND INSERT HEATER DUCT THRU HOLE IN BAFFLE.
2. AFTER 369D26542 BAFFLE IS INSTALLED, DISCONNECT AND
ROUTE DRAIN TUBE THRU HOLE IN BAFFLE.
3. IF EXCESSIVE GAP (0.06 X 1.00 OR MORE)EXISTS BETWEEN
STRUCTURE AND RUBBER EXTENSION ON SEALS, FILL GAP BY
BONDING STRIP OF ADHESIVEBACKED GASKET TO STRUCTURE.
4. NO. 10 SCREW HOLE IN FAIRING ON SHIPS. DO NOT USE THIS
HOLE TO INSTALL COVER OR FAIRING. G5330092
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies (Sheet 2 of 2)
Page 213
533000 Revision 38
MAINTENANCE MANUAL
Page 214
Revision 38 533000
MAINTENANCE MANUAL
Section
533030
Upper Aft Section
Fuselage (500/600N)
MAINTENANCE MANUAL
UPPER AFT SECTION FUSELAGE (500/600N)

NOTE: For all the following items, refer to Sec. the engine plenum chamber area. With the
533000. installation of a particle separator, ejector
Upper Firewall outlets are positioned on each side of the
Firewall and Plenum Chamber Panels plenum cover.
General Inspection
Mast Support Structure On the 500N, the R/H side of the aft fairing is
Main Rotor Mast the inlet bypass door which remains on the
Firewalls fuselage when the aft fairing is removed.
Firewall Insulation and Soundproofing On the 600N, the inlet bypass door is just aft
of the mast assembly and just forward of the
1. Engine/AntiTorque Air Inlet Fan Fairings engine plenum access cover.
When working near or around
CAUTION engine air and cooling inlets,
A removable fan hub and transmission gear
box fairing is also located in the fan plenum
use care to prevent entry of foreign objects. chamber.
(Ref. Figure 201) On the 500N, the engine air For general maintenance practices for the
inlet fairing on top of the fuselage structure upper aft section (Ref. Sec. 533000).
directs ambient outside air to the engine air
inlet and the oil cooler blower. The fairing 2. Engine Air and Fan Inlet (Plenum
installation consists of a forward fairing Chamber Area) Inspection
section and an aft fairing section. Right and
left halves of forward fairing are removable. (Ref. Figure 201 and Figure 202)
(Ref. Figure 202) On the 600N, the engine air Avoid FOD, Cover compressor
CAUTION inlet prior to working in plenum
inlet fairing on top of the fuselage structure
directs ambient outside air to the engine air chamber area. Vacuum all FOD debris out of
inlet bypass door and the oil cooler blower. The the plenum chamber before removing the
fairing installation consists of a forward inlet protective cover from the inlet bell. Severe
fairing sections and an aft fairing section. The damage to the engine may result from entry
controls cover and right and left halves of of foreign objects.
forward fairing are removable.
(1). Open the plenum chamber bypass door
On the 600N, the engine inlet or particle by pulling the handle located in the
separator is mounted aft of the inlet fairings cockpit. Open the engine access doors to
and wraps around the engine plenum for inspect the rear side of the plenum
increased air flow due to the larger engine panels.
installation. (2). For access, remove the fan air inlet
The aft section consists of an air inlet screen screen and engine plenum fairing
on top of the fuselage structure which directs assemblies.
ambient air to the antitorque fan assembly. (3). Inspect all panels for evidence of
The engine plenum access cover bolted to the corrosion, punctures and security of
fuselage and is removable to provide access to rivets and fasteners.
the engine plenum, particle separator and mist
eliminator (optional equipment) if installed. (4). Inspect the engine air inlet bypass door
attaching hardware and installation
The engine plenum access cover on the 600N (Ref. Sec. 711010, Engine Air Intake
helicopter mounts to the aft end of the particle System).
separator/bypass door frame. The plenum
cover directs air downward for the engine air (5). Inspect engine air shield mounting for
intake and when removed provides access to secure attachment.
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533030 Revision 26
MAINTENANCE MANUAL
FAN AIR INLET

SCREEN
ENGINE PLENUM AC-

CESS COVER
INTAKE FAIRING AC-

CESS DOOR
BYPASS DOOR
PIN
INTAKE FAIR-
INGS
COTTER
PIN
BYPASS DOOR
LATCH ASSEMBLY
FAN HUB FAIRING AND
TRANSMISSION COVER
G533005A
Figure 201. Upper Aft Section (500N)
Page 202
Revision 34 533030
MAINTENANCE MANUAL
ENGINE PLENUM
ACCESS COVER
ENGINE INLET SCREEN OR

PARTICLE SEPARATOR
FORWARD INLET
FAIRINGS
CONTROLS FAIRING
PARTICLE SEPARATOR/
BYPASS DOOR FRAME
MID UPPER
STRUCTURE
EXTENDED FUSELAGE
ROOF BEAMS OF 600N
MAST SUPPORT STRUCTURE
3040010101
3011010303
6G53055
Figure 202. Upper Aft Section Fuselage (600N)
Page 203
533030 Revision 34
MAINTENANCE MANUAL
(6). Inspect aft section strut for rivets B. Upper Fuselage Controls Fairing
corrosion and edge clearance where it Installation
passes though cutout in forward panel.
(1). Inspect upper fuselage controls fairing
(7). Inspect engine air cooling inlet screen for cracks, delaminations and overall
for damage, seal deterioration and general condition.
security. (2). Position controls fairing to align with
(8). Inspect fan transmission driveshaft holes in mounting surfaces.
tube fairing and access panel for dents, (3). Install attaching hardware.
buckled or wrinkled areas and signs of
corrosion. 5. Engine Inlet Fairings Replacement
(9). Inspect the fan inlet screen mesh for The R/H and L/H engine inlet fairings are
condition and security. made of a lightweight Kevlar fabric and are
used on the 500/600N installation only.
(10). If fan inlet screen needs repair, re-
welded using 0.063 inch (1.600 mm) A. Engine Inlet Fairing Removal
annealed cres 302 or 304 wire per (1). Remove hardware from lefthand inlet
AMS5336 or AMS5639. fairing and remove fairing.
(11). Visually inspect through the fan inlet (2). Remove hardware from righthand
screen for security of the transmission inlet fairing and remove fairing.
fairing and FOD.
B. Engine Inlet Fairing Installation
(12). Ensure that forward removable inlet
fairings and engine access doors are (1). Inspect fairings for cracks, delamina-
secure. tions and condition of pressure sensi-
tive tape.
A. Upper Aft Section General Repair (2). Install righthand inlet fairing and
attaching hardware.
(Ref. FAA AC 43.131A & 2A and Structure
Repair Manual for additional repair proce- (3). Install lefthand inlet fairing and
dures. attaching hardware.
3. Upper Fuselage Controls Fairing (600N) (4). Ensure that 11/2 threads protrude
through nutplates.
The Upper Fuselage Controls Fairing covers
the flight control rods that travel longitudinal- 6. AntiTorque Fan Air Inlet Screen
ly aft along the roof of the fuselage for the Replacement
rotor collective and cyclic controls. A. Fan Air Inlet Screen Removal
4. Upper Fuselage Controls Fairing (1). Remove attaching hardware and
Replacement (600N) remove air inlet screen.
The Upper Fuselage Controls Fairing is made B. Fan Air Inlet Screen Installation
of a lightweight Kevlar fabric and is used on (1). Install air screen and attaching
the 600N installation only. hardware.
A. Upper Fuselage Controls Fairing 7. Fan Hub and Transmission Cover Fairing
Removal Replacement
(1). Remove hardware that attaches upper A. Fan Hub and Transmission Cover
fuselage controls fairing to mounting Removal
surfaces.
(1). Remove attaching hardware on the fan
(2). Remove controls fairing. hub transmission fairing.
Page 204
Revision 34 533030
MAINTENANCE MANUAL
B. Fan Hub and Transmission Cover (2). Install hardware attaching plenum
Installation cover to structure.
(1). Inspect fairing for cracks and general
condition. 9. Tailboom Attach Fitting Inspection
(2). Install attaching hardware. (Ref. Figure 203) Inspect the upper lefthand
and righthand tailboom attach fittings,
(3). Check for minimum runon torque of angles and nutplates as follows:
attaching screws, 2 inchpounds
(0.226 Nm) minimum. (1). Remove button plug from attach fitting
access cover.
8. Engine Plenum Access Cover
Replacement
(2). Using a bright light, inspect fitting and
Avoid FOD, Cover compressor angle:
chamber area. Vacuum all FOD debris out of (a). Inspect attach fittings for cracks.
the plenum chamber before removing the
protective cover from the inlet bell. Severe NOTE: Pay particular attention to area around
damage to the engine may result from entry aft rivet holes. No cracks are allowed.
of foreign objects.
(b). Inspect angle for cracks.
A. Engine Plenum Access Cover Removal
NOTE: If particle separator is installed, ejector (c). If any cracks are found in attach
ducting is not removed with plenum access fitting or angle, contact MDHI Field
cover. Service Dept. for replacement
instructions.
(1). Remove hardware that attaches engine
plenum access cover to supporting (3). Inspect nutplate for thread damage and
structure. cracks.
(2). Remove plenum cover. NOTE: Cracks would appear from top of self
B. Engine Plenum Access Cover Installation locking nut split to base of nut.
(1). Position engine plenum access cover to (a). Replace nutplate if threads are
align with mounting holes in fuselage. damaged or cracked.
Page 205
533030 Revision 34
MAINTENANCE MANUAL
50N3422 TAILBOOM ATTACH FITTING

(RIGHT SIDE SHOWN)
500N34296 ANGLE
(RIGHT SIDE SHOWN)
6G53103
Figure 203. Tailboom Attach Fitting Inspection
Page 206
Revision 34 533030
MAINTENANCE MANUAL
10. Lower Longeron Inspection (L158, R158) 11. Forward Upper Longeron Inspection
(L137, R137)
(Ref. Figure 204) Inspect the lower lefthand
and righthand longerons as follows: (Ref. Figure 204) Inspect the foreword upper
lefthand and righthand longerons as follows:
(Ref. Section 910000) Consumable Materials
Item Nomenclature (Ref. Section 910000)
CM425 Sealing compound Item Nomenclature
(1). Remove button plugs (L158, R158) from
side of helicopter.
(1). Remove button plugs (L137, R137) from
(2). Using bright light and mirror, or side of helicopter.
borescope, inspect the longeron, Sta.
155.75 frame and Cant. Sta. 159.97 (2). Using a borescope, inspect the longeron
frame for cracks. and Sta. 137.50 frame for cracks.
(3). If any cracks are found, contact MDHI (3). If any cracks are found, contact MDHI
Field Service Dept. for repair instruc- Field Service Dept. for repair instruc-
tions. tions.
(4). Install button plugs in inspection hole (4). Install button plugs in inspection hole
and seal with sealing compound and seal with sealing compound
(CM425). (CM425).
Page 207
533030 Revision 34
MAINTENANCE MANUAL
UPPER LONGERON, FWD

(L137, R137)
LOWER LONGERON
(L158, R158)
0.75 IN. (19.05 MM)

HOLE IN HOLE IN SKIN
STA. 146.62
NOTE
NOTE
LOWER LONGERON UPPER LONGERON FWD

(VIEW LOOKING DOWN) (VIEW LOOKING UP)
NOTE: AREAS WHERE CRACKS

ARE MOST LIKELY TO APPEAR. G533013
Figure 204. Inspection Hole Locations
Page 208
Revision 34 533030
MAINTENANCE MANUAL
12. Control Tunnel (FS 78.50) Beam (3). Using a mirror and bright light, inspect
Inspection tunnel beams, both sides, for cracks in
the rivet area; no cracks allowed.
(Ref. Figure 205) If cracks are found, contact MDHI field
service department for repair instruc-
(1). Remove TyRaps securing boots to tions.
control tubes and shelf assembly. (4). Slide boots down over shelf assembly
and secure top and bottom of boots with
(2). Slide boots up to top of tubes. TyRaps.
NOTE 2
369D 225087 WEB
NOTE 1
369H2564 TUNNEL BEAM
369D225085 WEB
NOTE:
1. INSPECT THESE AREAS FOR CRACKS (BOTH SIDES OF TUNNEL).
2. REMOVE CONTROL TUBE BOOTS TO GAIN ACCESS FOR INSPECTION. G533014
Figure 205. Control Tunnel (FS 78.50) Beam Inspection
Page 209
533030 Revision 34
MAINTENANCE MANUAL
Page 210
Revision 34 533030
MAINTENANCE MANUAL
Section
534000
Tailboom
(369D/E/FF)
MAINTENANCE MANUAL
TAILBOOM
1. Tailboom General (8). Remove nuts and washers from bolts
that attach boom to fuselage. Remove
(Ref. Figure 201) The tailboom assembly, a lower bolts first and top bolt last; then
monocoque structure of aluminum skin over remove boom.
forged aluminum frames, houses the tail rotor
drive shaft and tail rotor control rod, and B. Tailboom Installation
supports the horizontal and vertical stabiliz-
ers. Consumable Materials
2. Tailboom Replacement Item Nomenclature
A. Tailboom Removal CM103 Solid film lubricant
Special Tools
Special Tools
Item Nomenclature
Item Nomenclature
ST2010 Adapter, torque wrench
ST1005 Insertion/extraction tool
ST1006 Insertion/extraction tool
(1). Support tailboom so that mating
bulkheads are flush.
(1). Remove vertical stabilizer (Ref. Sec.
535010). NOTE: Prior to tailboom installation, coat
threads of external wrenching bolts and at-
(2). Remove tail rotor transmission and tail taching nuts with lubricant (CM103).
rotor drive shaft as a unit (Ref. Sec.
(2). Slide countersunk washers on external
631500).
wrenching bolts with countersunk side
(3). Remove tail rotor control rod (Ref. Sec. facing bolt heads.
672010). If washers are installed back-
CAUTION wards, structural failure may
(4). (369FF Model Only) Remove tailboom
extension (Ref. Tailboom Extension result due to insufficient surface in bearing
Replacement). that can cause spreading or cracking of
washers and result in loss of clampup
(5). Position suitable cradles under tail- torque.
boom at Cant. Sta. 209.78 frame fitting
(3). Install bolts through aft section
and the forward stabilizer boom
fuselage frame into boom frame and
mounting frame (Cant. Sta. 273.00)
place flat washer(s) on each bolt as
(Ref. Figure 202).
required for correct bolt grip. Use no
To avoid damage, ensure that more than three flat washers under
CAUTION boom is properly supported be- each nut. Install nuts and torque only
fore removing boom attach bolts. the nuts to 380 410 inchpounds
(42.93 46.32 Nm).
(6). Open boom bolts access doors and
remove bond jumper from boom. NOTE: Bolts may be reversed for access to
torque nuts. Torque wrench adapter
(7). Disconnect connector of chip detector (ST2010) or a thinwalled deep socket is
wiring and night lighting system used for torquing.
wiring. Disconnect knife splice by hand (4). Install vertical stabilizer.
or use appropriate connector insertion/
extraction tool (ST1005 or ST1006) for (5). (369FF Model Only) Install tailboom
wire mate type connector. extension.
Page 201
534000 Revision 19
MAINTENANCE MANUAL
STABILIZER MOUNTING
FITTINGS
GROMMET
GEARBOX AND STABILIZER
WIRING CONDUIT MOUNT FRAME
GROMMET
FORWARD STABILIZER BOOM
RIGHT SKIN PANEL MOUNTING FRAME
GROMMET STA. 264.32

CANT. FRAME
STA. 209.78
CANT. FRAME
STA. 242.14
CANT. FRAME NUT
WASHER
LEFT SKIN PANEL
STA. 219.96
CANT. FRAME
FORWARD STABILIZER
BOOM MOUNTING FRAME TAILBOOM
EXTENSION
STA. 197.78 CANT. GEARBOX AND STABILIZER

FRAME FITTING MOUNT FRAME
369FF ONLY
G534000
Figure 201. Tailboom Assembly and Tailboom Extension

(6). Install tail rotor transmission and tail (3). Remove tailboom extension from
rotor drive shaft as a unit. tailboom assembly.
(7). Install control rod. (4). Apply primer (CM318) in holes, on

faying surfaces and on the grip area of
(8). Perform tail rotor control rigging (Ref. the mounting studs and install tail-
Sec. 672010). boom extension while primer is still
wet.
(9). Install bond jumper to boom and
connect chip detector wiring. Connect NOTE:
night lighting wiring.
D Note the drag torque for each nut and its
location on the extension, in the helicop-
3. Tailboom Extension Replacement (369FF)
ter for later use.
(Ref. Figure 201) D Torque nuts while primer is still wet.
(5). Install tailboom extension on tailboom

Consumable Materials assembly and secure with four washers
(Ref. Section 910000) and four nuts.
Item Nomenclature
CM318 Primer (6). Torque nuts to 75 95 inchpounds
(8.47 10.73 Nm) plus drag torque.
(1). Remove tail rotor transmission and tail (7). Apply torque stripe paint.
rotor drive shaft as a unit (Ref. Sec.
631500). (8). Between 2 and 10 hours of helicopter
operation (to allow parts to seat), check
(2). Remove four nuts and four washers the torque of each mounting nut as
from tailboom assembly. follows:
Page 202
Revision 19 534000
MAINTENANCE MANUAL
(a). Using the drag torque previously (4). Inspect bond jumper for security and
measured and noted, apply a torque corrosion.
load of 95 3 inchpounds (10.73
0.34 Nm) plus the noted drag (5). Inspect boom exterior for loose or
torque (noted at each individual missing rivets.
nut) to each mounting nut of the
extension. (6). Inspect boom and gearbox stabilizer
mounting frames for cracks, security of
(b). Reapply torque stripe paint. attachment, elongated holes or condi-
tion of mounting studs.
(9). Install tail rotor driveshaft and tail
rotor transmission as a unit.
(7). Replace damaged or deformed studs
4. Tailboom Inspection (Ref. CSPSRM6, Structural Repair
Manual).
(Ref. Figure 201)
5. Tailboom Repair
(1). Inspect boom interior skin and frames
for corrosion and cracks. There is no damage that can be
CAUTION considered negligible. All dam-
(2). Check attaching nuts and bolts in boom
Cant. Sta. 197.78 frame fitting for age must be repaired upon detection (Ref.
security. CSPSRM6, Structural Repair Manual).
(3). Inspect tail rotor control rod grommets NOTE: The skins forming the monocoque boom
in boom frames for evidence of deterio- assembly are highly stressed (Ref.
ration. Figure 201).
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534000 Revision 19
MAINTENANCE MANUAL
FORWARD STABILIZER
BOOM MOUNTING FRAME
(CANTED STA 273.00)
CANT. STA 209.78
SELFLOCKING NUT
FLAT WASHER (CRES)
NUT
PLAIN HEX NUT (NOTE 4)
FLAT WASHER (ALALY
UNTREATED)
SPRING LOCKWASHER
FLAT WASHER(S)
BOND JUMPER
(NOTE 2)
SPRING LOCKWASHER (NOTE 1)
FLAT WASHER
(ALALY UNTREATED)
FLAT WASHER
(NOTE 2) ACCESS HOLE
COUNTERSUNK WASHER CHIP DETECTOR WIRING
TAIL LIGHT WIRING

EXTERNAL WRENCHING BOLT (NOTE BOOM FITTING
4)
JUMPER CONNECTION
ACCESS HOLE
TAILBOOM ATTACHMENT
BRACKET
FLAT NOTES:
WASHER 1. ENSURE THAT GROUND CONTACT SURFACE IS CLEAN
BEFORE BOND JUMPER INSTALLATION. AFTER
SPRING LOCKWASHER
INSTALLATION, COAT EXPOSED BARE METAL GROUNDED
FLAT WASHER (CRES)
AREA WITH LACQUER (CM306).
(NOTE 1) BOND JUMPER 2. THREE FLAT WASHERS MAXIMUM UNDER NUT. WASHERS
FLAT WASHER ADDED UNDER BOLT HEAD. COUNTERSUNK WASHER IS
(ALALY UNTREATED)
REQUIRED.
BOOM FITTING BRACKET AND 3. CRESCORROSION RESISTANT STAINLESS STEEL.
JUMPERINSTALLATION 4. PRIOR TO INSTALLATION, COAT THREADS
WITH LUBRICANT (CM103).
G534001A
Figure 202. Tailboom Installation and Removal
Page 204
Revision 19 534000
MAINTENANCE MANUAL
Section
534030
Tailboom (500/600N)
MAINTENANCE MANUAL
TAILBOOM (500/600N)
1. Tailboom Description (8). A Strake, a composite strip bonded to
the left side of the tailboom, breaks up
(Ref. Figure 201) The tailboom assembly is a airflow on the left side of the boom for
fully monocoque construction of graphite hovering stability.
composites, it provides directional control for
the helicopter. (9). A Stator located directly behind the fan
and mounted inside the tailboom
The tailboom for the Model 600N helicopter is straightens low pressure air flowing
a similar version to that on the Model 500N through the boom. The stator has
helicopter. One of the obvious differences is the eleven composite removable blades, and
length, approximately 28 inches (71.12 cm) is accessible by removing the tailboom.
longer on the 600N. Also, two of the four
mounting bolts that hold the boom to the (10). A tail skid mounted bottom aft on the
fuselage are a larger diameter. These two tailboom is constructed of aluminum
points have been reinforced both on the boom tubing.
and on the fuselage for added strength.
(11). A jack pad is located on the tailboom
(1). The tailboom converts energy from the underside. The jackpad can be accessed
main rotor downwash to an antitorque by removing the tail skid.
force. In order to accomplish this, a
variable pitch fan pushes low pressure (12). The tailboom provides for the mounting
air through two longitudinal slots on of the horizontal stabilizer and a control
the right side of the tailboom and two cable conduit for the flight controls.
thrusters ports at the end of the
tailboom. These slots located at 130 2. Tailboom Replacement
and 76 degrees, direct low pressure air
downward over the tailboom surface. (Ref. Figure 201)
(2). Slot air flow mixes with main rotor NOTE: When removing tailboom as an assem-
downwash air, delaying its separation bly with the horizontal and vertical stabiliz-
at the bottom of the tailboom and ers installed, precaution should be taken to
effectively creating a lifting force. adequately support and balance the tail-
boom assembly equally due to the mass of
(3). Air from the main rotor passing over the stabilizers.
the boom provides directional control to
neutralize the main rotor torque. A. Tailboom Removal
(4). Approximately 60% of the antitorque (1). Remove tailboom fairing.
force required in a hover, is provided by
the tailboom lift, the remaining 40% is (2). Disconnect the forward end of the
by metered air flowing out the end of antitorque control cable by turning
the tailboom rotating thruster cone. outside collar sleeve counterclockwise
and back to expose the inner cable.
(5). A stationary thruster cone port directs Apply sufficient right pedal to expose
air flow to the left or to the right. engagement pin and pull collar sleeve
outward.
(6). The rotating thruster cone (a can
shaped structure) meters exit air for (3). Disconnect electrical connector.
left or right directional control.
(4). Have assistants support tailboom.
(7). Pedal movement opens and closes the
thruster cone ports and changes fan (5). Remove four mounting bolts and
blade pitch angle for engine power washers and remove tailboom. Inspect
changes. bolts for corrosion.
Page 201
534030 Revision 36
MAINTENANCE MANUAL
500N TAILBOOM SHOWN G5340021A
Figure 201. Tailboom Assembly (Sheet 1 of 3)
Page 202
Revision 19 534030
MAINTENANCE MANUAL
FITTING
COLLAR
PIN
LARGER DIAMETER
MOUNTING HOLE
600N TAILBOOM SHOWN
LARGER DIAMETER
MOUNTING HOLE
G5340022C
Figure 201 Tailboom Assembly (Sheet 2 of 3)
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534030 Revision 22
MAINTENANCE MANUAL
500N THRUSTER SHOWN
G5340023
Figure 201 Tailboom Assembly (Sheet 3 of 3)
Page 204
Revision 19 534030
MAINTENANCE MANUAL
B. Tailboom Installation 150 inchpounds (14.68 16.94

Nm) plus drag torque and the two
Before tailboom installation, in- larger diameter bolts to 180 220
CAUTION spect radius blocks for brinnel- inchpounds (20.33 24.85 Nm)
ing, corrosion, cracks and indication of in- plus drag torque. Safety bolts.
dent on face; none allowed.
RN003 RN059 with TB600N007
NOTE: If installing a new tailboom, the complied with and RN060 & subs;
500N35005 cover will have to be installed torque bolts to 180 220 inch
after internal tailboom components are pounds (20.33 24.85 Nm) plus
installed (Ref. 500N35005 Cover Installa- drag torque. Safety bolts.
tion). (5). Check for a minimum of two threads
(1). Support tailboom so that the mating protruding from nutplates.
bulkhead surfaces are flush. (6). Using a 0.002 inch (0.051 mm) feeler
gauge, check for gap between tailboom
(2). Slide countersunk/chamfered washers and fuselage flange within 0.60 inch
on external wrenching bolts with (15.3 mm) of centerline of each of the
countersunk side facing bolt head. four attach bolts; no gap allowed.
If washers are installed back- (7). Reconnect electrical connectors.
CAUTION wards, structural failure may (8). Reconnect control cable assembly.
result due to insufficient surface in load
bearing area that can cause spreading or (9). Install tailboom fairing.
cracking of washers and result in loss of 3. Tailboom Inspection
clampup torque. (Ref. Figure 201)
(3). 600N: (1). Inspect tailboom exterior as follows:
Install washer on bolt after the counter- (a). Inspect tailboom fairing for cracks
sunk washer. and delaminations.
(b). Inspect tailboom flange and mount-
(a). Install either an AN960C516 or ing bolt holes attachment area for
NAS1149C0563R washer on 5 bolts. cracks at Sta. 168.20.
(b). Install either an AN960C616 or (c). Inspect radius blocks for brinneling,
NAS1149C0663R washer on 6 bolts. corrosion and indication of indent on
face; none allowed. If found, scrap
Do not lubricate tailboom attach radius block and install new radius
CAUTION bolts or nutplates, this will block.
cause a false torque reading and lead to bolt
loosening. (d). Inspect strake for cracks, delamina-
tions, debonding, dents, nicks and
(4). With the tailboom supported in place, separation.
install four bolts with washers. NOTE: Damage to slots can cause significant
degradation of aircraft performance in a
(a). 500N: hover.
Torque bolts to 130 150 inch (e). Inspect tailboom surface area and
pounds (14.69 16.95 Nm) plus tailboom circulation control slots
drag torque. Verify minimum run surface area for cracks, voids, dents,
on torque of 6.5 inchpounds (0.73 holes, scratches, separation, delami-
Nm). nations at tailboom and security.
(b). 600N: 1). Using a bright light, inspect fore
and aft radii of the lower portion of
RN003 RN059 without the three upper slot bridges for
TB600N007 complied with; torque cracks, illuminate area under the
the two smaller diameter bolts to 130 flap.
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MAINTENANCE MANUAL
1.25 IN. (3.175 CM) CRACK

LENGTH PERMISSIBLE
1.25 IN. (3.175 CM) CRACK

LENGTH PERMISSIBLE
6G53102A
Figure 202. Tailboom Flap Inspection

NOTE: The flap may be raised slightly, using to the forward inboard legs) and
finger pressure only, to aid in checking this attachment fittings for cracks, voids,
area. separation and delamination.
(f). Inspect flaps for cracking and (h). Inspect stabilizers (Ref. Sec.
debonding (Ref. Figure 202): 535030).
(i). Inspect (tailskid) for cracks, dents,
1). A crack of any length, in line with holes and delamination.
aft edge of flap, is permissible at
interface between flap and tail- (j). Inspect rotating thruster cone for
boom. freedom of operation, cracks, holes,
separation and delamination.
2). A crack of 1.25 inch (3.175 cm)
maximum length, in line with the (k). Inspect tailboom grommets (2) places
forward edge of flap, is permissible for cracks and proper fit.
at interface between flap and
tailboom. (2). Inspect tailboom interior as follows:
(a). Check stator vanes and stator
NOTE: If crack in forward edge of flap is longer diffuser cone for cracks, delamina-
than 1.25 inch (3.175 cm), contact your local tions and separation.
MDHI Field Service Representative for dis-
position. 1). Maximum allowable cracks found
emanating from stator vane inserts
(g). Inspect horizontal stabilizer mount- should not exceed 0.10 inch (2.54
ing brackets (pay particular attention mm) spanwise.
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Revision 39 534030
MAINTENANCE MANUAL
2). No cracks allowed running cord 6. Stator Blade Replacement

wise towards leading or trailing
edge (Ref. Figure 201, View E)
(1). Stator Blade Removal: Remove two
(b). Inspect slot air foils for cracks,
selflocking screws and two surface
delamination and separation from
washers.
boom.
(2). Stator Blade Installation: Install two
(c). Inspect control cable assembly surface washers and two selflocking
attachment points for looseness, screws. Torque screws to 3 6 inch
cracks and condition. pounds (0.34 0.68 Nm) plus drag
(d). Inspect cable conduit for cracks, torque. Total torque should not exceed
separation and delamination. 15 inchpounds (1069 Nm) total
torque.
(e). Inspect air circulation area for FOD
and cleanliness. If necessary, clean 7. Rotating Thruster Cone Replacement
with mild soap and water. (Ref. Figure 201, View H)
(3). Inspect rotating thruster cone collar A. Rotating Thruster Cone Removal
strap ring rivets for looseness, strap for
cracks and condition. (1). Remove cone tip cap by removing eight
screws and washers.
4. Tailboom Repair (2). Support rotating thruster cone and
There are no repair procedures for the remove three bolts and washers that
tailboom at this time. Refer to MDHI Field attach the rotating thruster cone,
Service Representative. carefully slide rotating cone aft to clear
stationary cone, bearings and followers
5. Stator Replacement and the cable and drum assembly.
(Ref. Figure 201, View D) B. Rotating Thruster Cone Installation
A. Stator Removal (1). Carefully slide rotating thruster cone

over stationary cone, bearings, rollers
(1). Remove tailboom. and followers.
(2). Note or index top of stator for reas- (2). With the thruster supported in place,
semble. Support stator and remove install three bolts with washers
seven exterior screws and washers attaching the rotating thruster to
mounted around the forward part of the thruster gear box. Torque bolts 70 90
tailboom. inchpounds (7.91 10.17 Nm).
Safety wire bolts.
B. Stator Installation
(3). Install cone tip cap with eight screws
(1). Support stator and align stator vanes in and washers, torque screws per general
tailboom, install seven screws and aircraft practices.
washers, torque screws to 3 6 inch
pounds (0.34 0.68 Nm) plus drag 8. Rotating Thruster Cone Inspection
torque. Total torque should not exceed (1). Inspect for cracks and separation of
15 inchpounds (1069 Nm) total composite laminates.
torque.
(2). Check for freedom of rotational move-
(2). Install tailboom. ment within the control range of
thruster.
(3). Verify that stator does not rub against
the fan and for clearance of 0.0200.080 (3). When the thruster is removed from
inch (0.5082.032 mm) between stator helicopter, check roller surface area
and fan. (strap) for cracks and condition.
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534030 Revision 39
MAINTENANCE MANUAL
NOTE: Refer to MD Helicopters Inc. Represen- washer and bolt, torque bolt per
tative for structural repairs, cracks, etc. standard aircraft torque values and
safety wire.
9. Stationary Thruster Cone Replacement
(4). Install thruster cone fairings.
(Ref. Figure 201)
(5). Install rotating thruster (Ref. Rotating
A. Stationary Thruster Cone Removal Thruster Cone Installation).
(1). Remove rotating thruster cone (Ref. 10. Stationary Thruster Cone Inspection
Rotating Thruster Cone Removal).
(1). Inspect for cracks and delamination of
(2). Remove eight off wing screws from pan composites structure for the following:
cover, remove cotter pin, nut and Internal ducts, air foil supports, pan
washer from sector input shaft and cover and pan (hat section).
remove pan cover. Remove washer and
bushing from sector bellcrank input (2). Inspect rollers and bearings for condi-
shaft. tion and freedom of rotation. Inspect for
cleanliness.
(3). Remove bolt, washer and bushing from
thruster input sector bellcrank clevis (3). Inspect sector bellcrank, cable assem-
(Ref. View J). blies, pulleys and support brackets for
condition, inspect of cleanliness.
(4). Remove thruster cone fairings.
(4). Inspect upper input shaft for damage
(5). Support stationary thruster cone and and wear. Check for play in mounting
remove eight bolts and washers, with pins. If mounting pins are found to
cable assembly attached to cone, have play, replace with new pins and
carefully lift cone off tailboom so that collars.
the control rod passes through the
thruster cone cutout. (5). Inspect thruster aft support shaft for
damage and wear. Check for play in
B. Stationary Thruster Cone Installation mounting hardware. If top bolt is found
to be loose, retorque to 10 15 inch
(1). Support stationary thruster cone to pounds (1.13 1.69 Nm). If bottom
tailboom so that the control rod passes mounting pins are found to be loose,
through the cutout of the stationary replace with new pins and collars.
cone, and that the mating surfaces are
flush to the tailboom. Slide counter- 11. Conduit and Support Strap Rebonding
sunk/chamber washers on external
wrenching bolts with countersunk side (Ref. Figure 203) The following procedure is for
facing bolt head. rebonding of the conduit supports.
If washers are installed back-

CAUTION wards, structural failure may Consumable Materials
result due to insufficient surface clampup (Ref. Section 910000)
in load bearing areas that can cause spread- Item Nomenclature
ing or cracking, resulting in loss of clamp CM217 Isopropyl alcohol
up torque. CM402 Adhesive
(2). With the stationary thruster cone
support in place, install eight bolts and (1). Lightly abrade faying surfaces with
washers. Torque bolts 30 40 inch Scotchbrite until surface gloss of the
pounds (3.39 4.52 Nm) plus drag laminate is gone.
torque.
(2). Solventwipe parts using a clean
(3). Connect control rod to input sector lintfree cloth dampened with isopropyl
bellcrank clevis and install bushing, alcohol (CM217).
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Revision 39 534030
MAINTENANCE MANUAL
(3). Wipe dry using a clean, lintfree, dry NOTE: Adhesive must be applied within 2
cloth and allow to air dry for 15 min- hours of preparation. If more than 2 hours
utes at ambient temperature. elapse before adhesive application, repre-
pare surfaces.
Do not heat conduit to more
CAUTION than 170F (77C). Conduit and (5). Mix adhesive (CM402) according to
tailboom can be damaged from too much manufacturers instructions and apply
heat. to faying surfaces.
(4). If conduit is bent away from tailboom, (6). Secure parts together with light
heat conduit to make more flexible for pressure and allow to cure for 24 hours
rebonding. at ambient temperature.
FS 263.916
CANT
A C
A B
FS 168.200 C
CANT
BL BL
0.000 0.000
38 28 APPLY ADHESIVE HERE

28 20
TAILBOOM
SUPPORT
APPLY
ADHESIVE APPLY
HERE ADHESIVE
HERE
CONDUIT
APPLY
ADHESIVE
HERE
SECTION BB
SECTION AA
LOOKING AFT SECTION CC
LOOKING FORWARD
500N TAILBOOM SHOWN G534004A
Figure 203. Conduit and Support Strap Rebonding
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534030 Revision 39
MAINTENANCE MANUAL
12. Horizontal Stabilizer Mount Fitting (8). Locate new fitting on tailboom.
Replacement
(9). Backdrill fittings to 0.1860.188 inch
(Ref. Figure 201) (4.7244.775 mm).
(10). Remove fitting and deburr rivet holes.
Empennage Fitting Part No.
L/H, Aluminum 500N35303, 7
(11). Touch up rivet holes with solid film
lubricant (CM101) for steel fittings or
R/H, Aluminum 500N35304, 8 chemical coating (CM206) for alumi-
L/H, CRES 500N35309 num fittings.
R/H, CRES 500N353010
(12). Steel fittings only:
(a). Using abrasive paper (CM801),
lightly abrade tailboom where fitting
is to be mounted.
Item Nomenclature
CM101 Solid film lubricant (b). Clean fitting and tailboom abraded
CM206 Chemical coating area with 1,1,1Trichloroethane
(CM222).
CM304 Enamel, epoxy (c). Prime fitting with adhesive primer
CM315 Adhesive primer (CM315).
CM318 Primer (d). Apply a thin layer of cement (CM418)
CM418 Cement, epoxy between fitting and tailboom.
CM425 Sealing compound NOTE:
D Use HTS1264/5 pin rivets with
HTS1176DU6AWU collars or alternate
(1). Remove horizontal stabilizer (Ref. Sec. HTS4864/5 pin rivets with
535030, Horizontal Stabilizer HST20006AW collars.
Replacement). D Gage rivet holes to ensure proper length
pin rivets.
(2). Remove rotating thruster cone (Ref.
Rotating Thruster Cone Replacement). (13). Relocate fitting on tailboom and install
with pin rivets wet with primer
(3). Remove stationary thruster cone (Ref. (CM318).
Stationary Thruster Cone
Replacement). (14). Seal edges around fittings with sealing
compound (CM425).
(4). Remove collars from pins in mount
fittings. (15). If installing steel fittings, prime with
adhesive primer (CM315).
(5). Drive pins out of fittings.
(16). Touch up with paint (CM304).
Do not allow fittings to reach
CAUTION 200F (94C), damage to tail- (17). Reinstall stationary thruster cone (Ref.
Stationary Thruster Cone
boom composite material will occur. Replacement).
NOTE: Heating the fitting to 150F (66C) may (18). Reinstall rotating thruster cone (Ref.
assist in removing them from tailboom. Rotating Thruster Cone Replacement).
(6). Carefully pop fittings loose from (19). Reinstall horizontal stabilizer (Ref. Sec.
tailboom while not damaging fiberglass 535030, Horizontal Stabilizer
sheets under fitting. Replacement).
(7). Clean area with 1,1,1Trichloroethane (20). Check rigging of thruster (Ref. Sec.
(CM222). 672030).
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MAINTENANCE MANUAL
(21). Check rigging of vertical stabilizers (a). If tailboom is not previously marked,
(Ref. Sec. 672030). place a mark every 2.0 inches (50.8
mm) around cover and tailboom.
13. 500N35005 Cover Installation
(b). Do not bond the bottom 8.0 inches
(Ref. Figure 204) New tailbooms come with the (203.2 mm) on aft end of cover.
500N35005 cover separate. This cover must
be bonded in place after the wiring and cables (4). Abrade around the cover mating
are installed. surface with 240 grit abrasive cloth
(CM802) to remove gloss.
(Ref. Section 910000) NOTE:
Item Nomenclature D Use care to avoid damage to the fiber re-
CM222 1,1,1Trichloroethane inforcement.
CM410 Adhesive, epoxy (parts A & B) D Metallic faying surfaces do not require
CM802 Abrasive cloth, aluminum oxide abrading.
CM819 Kimwipe
(5). Using 240 grit abrasive cloth (CM802),
lightly abrade spots, where marked,
(1). With cutout facing down and forward, around the tailboom until the surface
gently role cover to shape of tailboom gloss is removed.
and position inside aft end of tailboom.
Slide cover in until aft end is flush with (6). Wipe abraded surfaces with kimwipes
tailboom. (CM819) dampened with
1,1,1Trichloroethane (CM222). Allow
NOTE: Right edge of cover should be just to the to air dry for 15 minutes.
right of the torque tube housing (8 to the
right of centerline). Left edge should be un- (7). Mix adhesive according to manufactur-
der the left horizontal stabilizer empennage ers instructions.
fitting.
(2). Check holes in cover to ensure they line
NOTE: Adhesive must be applied within two
hours of cleaning. Repeat solvent prep if
up with electrical connectors on
more than two hours elapses before bond-
tailboom.
ing.
(3). If holes do not line up with electrical
connectors, remove cover, role 180 and (8). Apply adhesive to abraded areas and
reposition in tailboom. position cover in tailboom. Clean up
excessive adhesive.
NOTE: Tailboom is manufactured with 1.0 x 1.0
inch (25.4 x 25.4 mm) spots marked for (9). Allow to cure per manufacturers
abrasion. instructions.
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534030 Revision 39
MAINTENANCE MANUAL
R/H HORIZONTAL CL
EMPENNAGE FITTING RIGHT EDGE OF
5 COVER
LEFT EDGE OF
5 COVER
8
TORQUE TUBE
HOUSING
RIGHT EDGE OF
5 COVER
U 5 COVER
P
TAILBOOM
LEFT EDGE OF
5 COVER
8.0 IN. (203.2 MM)

L/H HORIZONTAL DO NOT BOND
EMPENNAGE FITTING THIS AREA
VIEW LOOKING DOWN
G534005
Figure 204. 500N35005 Cover Installation

14. Tail Skid Replacement (a). Insert removed shims and install two
bolts and washers.
(Ref. Figure 205)
(b). Torque bolts to 36 40 Inchpounds
A. Tail Skid Removal
(3.95 4.52 Nm) plus drag torque.
(1). Remove two bolts with washers from aft
tail skid brace. (4). If installing a new tail skid:
(2). Retain shims between base and brace if (a). Install bolts finger tight, ensure gap
same tail skid is to be reinstalled. is even on both sides.
(3). Slide tail skid from forward bracket (b). Measure gap between brace and
assembly. base.
B. Tail Skid Installation (c). Subtract 0.010 in. (0.254 mm) and
peel shims to that thickness.
(1). Slide tail skid into forward bracket
assembly. (d). Insert shims between brace and base
(2). Install aft brace onto aft base. and torque bolts to 36 40 Inch
pounds (3.95 4.52 Nm) plus drag
(3). If reinstalling the same tail skid: torque.
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MAINTENANCE MANUAL
FORWARD BRACKET
ASSEMBLY AFT BASE
SHIM AFT BRACE

BOLT
WASHER
TAIL SKID
G534006
Figure 205. Tail Skid Installation
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534030 Revision 39
MAINTENANCE MANUAL
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Revision 39 534030
MAINTENANCE MANUAL
Section
535010
Stabilizer (TTail)
(369D/E/FF)
MAINTENANCE MANUAL
STABILIZER (TTAIL) (369D/E/FF)

1. Stabilizer General (1). Remove four screws securing tip plate
and tip weight (if applicable, right and
(Ref. Figure 201) The tail surfaces (empen- left tip plates and/or tip weights are
nage) stabilize the helicopter and maintain it interchangeable) to horizontal stabiliz-
in a relatively level attitude during high speed er.
forward flight. The tail surfaces consist of a
vertical and horizontal stabilizer attached to (2). Remove nuts and washers securing
the aft end of the tailboom. horizontal stabilizer to vertical stabiliz-
er fitting.
The horizontal stabilizer mounts atop of the
vertical stabilizer in a Tshaped arrangement. (3). Disconnect position light electrical
Tip plates are attached to ends of the horizon- connection and bond jumper.
tal stabilizer with a steel tip weight between
each tip plate and the stabilizer. The horizon- NOTE: MDHI Notice DN63 contains informa-
tal stabilizer is constructed of aluminum alloy tion relative to adding drain holes and seal-
skins riveted to formed ribs and spars. ing doubler edges on some 369D helicopters.
MDHI Notice DN44.1 contains informa-
The vertical stabilizer is constructed of tion relative to replacement of trailing edge
aluminum alloy skins bonded to formed spars. tabs, relocation of static pressure tube and
adding doublers to some 369D helicopters.
The vertical stabilizer includes fittings,
honeycomb core, and nonstructural leading (4). Inspect horizontal tip plates and
and trailing edges. The tip plates are con- stabilizer (Ref. Horizontal Stabilizer
structed of aluminum alloy skins bonded over and Tip Plate Inspection).
a honeycomb core. The vertical stabilizer is
mounted aft right of the tail boom and is B. Horizontal Stabilizer and Tip Plate
bolted to the gearbox and stabilizer mount Installation
frame and a upper and lower mount fitting.
The vertical stabilizer fitting supports the Consumable Materials
horizontal stabilizer. The lower end of the (Ref. Section 910000)
vertical stabilizer incorporates a tail skid Item Nomenclature
assembly.
Lighting provisions are provided on both
vertical and horizontal stabilizers. (Ref. Sec.
9640 contains information on exterior lights.) (1). Support helicopter at rear jackpoint
(Ref. Sec. 070000) when installing
A. Stabilizer Troubleshooting horizontal stabilizer to ensure that
helicopter angle of incidence does not
(Ref. Table 201) change during measurements.
2. Horizontal Stabilizer and Tip Plate (2). Measure inclination angle of horizontal
Replacement stabilizer at B.L. 10.66 inches (27.076
cm) to right (S RIGHT) and left (S
A. Horizontal Stabilizer and Tip Plate LEFT) of horizontal stabilizer center-
Removal line (Ref. Figure 202). If angles S
RIGHT and S LEFT differ by more than
(Ref. Figure 201) one degree, replace horizontal stabiliz-
er.
NOTE: Tip weights are installed at manufac-
turing and are only required to reduce T (3). For aircraft 0003D 0286D (Ref.
Tail vibration. Figure 204);
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535010 Revision 19
MAINTENANCE MANUAL
(a). Apply a 0.030 0.040 inch (0.762 (2). Torque bolts 190 220 inchpounds
1.016 mm) bead of sealant (CM425) (21.47 24.86 Nm); then lockwire bolts
around perimeter of top rib assem- in pairs.
blies and at attach fitting.
(3). Connect anticollision light electrical
NOTE: Do not seal drain holes. connection.
(b). Apply sealant around electrical (4). Install horizontal stabilizer, refer to
conduit and seal over tooling holes. (Ref. Horizontal Stabilizer and Tip
(4). Position horizontal stabilizer on vertical Plate Installation).
stabilizer fitting (Ref. Figure 201).
4. Horizontal Stabilizer and Tip Plate
(5). Connect position light electrical Inspection
connection and bond jumper.
(1). Inspect metal skin for holes, cracks,
(6). Install nuts and washers. Torque nuts loose rivets or corrosion. Any crack is to
to 90 110 inchpounds (10.17 be stop drilled or patched.
12.43 Nm).
(7). Check angle of incidence (Ref. Angle of (2). Inspect attach fittings and light
Incidence Measurement). mounting bracket for cracks, loose
rivets or corrosion.
(8). Install tip plates with tip weight
between tip plate and horizontal (3). Inspect attach studs and mating holes
stabilizer, using four screws. for evidence of wear caused by loose-
ness in service. Inspect questionable
(9). Remove support from rear jackpoint. studs by dyepenetrant or magnetic
particle method, as applicable.
3. Vertical Stabilizer Replacement
A. Vertical Stabilizer Removal (4). Inspect drain holes on lower surface.
Ensure they are not blocked or clogged
(Ref. Figure 201) with debris.
(1). Remove horizontal stabilizer (Ref. (5). Inspect seal around upper and lower
Horizontal Stabilizer and Tip Plates doublers. Ensure all gaps/edges
Removal). between doublers and stabilizer skin
(2). Disconnect anticollision light electrical are sealed.
connection.
(6). Repair horizontal stabilizer and tip
(3). Remove bolts and washers securing plates (Ref. Horizontal Stabilizer and
stabilizer to tailboom. Tip Plates Repair).
(4). Inspect vertical stabilizer (Ref. Vertical 5. Vertical Stabilizer Inspection
Stabilizer Inspection).
(1). Inspect skin for holes, cracks, bonding
B. Vertical Stabilizer Installation
separation or corrosion.
(Ref. Figure 201)
(2). Inspect attach fitting for cracks, loose
rivets or corrosion.
(Ref. Section 910000) (3). Inspect tail skid for cracks, deformation
Item Nomenclature and loose or missing rivets.
CM109 Molybdenum disulfide powder lubricant
(4). Inspect anticollision light bracket for
cracks, loose rivets or screws and
(1). Align stabilizer with mounting holes on corrosion.
the tailboom fitting. Spray bolt threads
with lubricant (CM109) and install. (5). Check condition of grommets.
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Revision 19 535010
MAINTENANCE MANUAL
POSITION LIGHT
BRACKET
HORIZONTAL GROMMET
STABILIZER
TIP WEIGHT
(NOTE 1)
HORIZONTAL
STABILIZER
VERTICAL ELECTRICAL
STABILIZER LEAD POSITION LIGHT
BRACKET ATTACHMENT
TIP PLATE
ANTICOLLISION
LIGHT SUPPORT
SEAL
0.1 X 0.75 X 2.0 INCH

(2.54 X 19.05 X 50.8 MM)
1 OZ (28.35 G) MS20470AD4 RIVET

LEAD WEIGHT (2 REQD)
(NOTES 2, 3, 4) HS306318 WASHER
(2 REQD) (NOTE 3)
GROMMET
SEAL
FORWARD
VERTICAL
SEAL
HORIZONTAL STABILIZER TAB STABILIZER
WEIGHT INSTALLATION FITTING
(421087505 STABILIZER ONLY)
NOTE:
1. TIP WEIGHTS ARE INSTALLED AT MANUFACTURING AND
ARE ONLY REQUIRED TO REDUCE TTAIL VIBRATION.
2. COMMERCIAL 1 OZ (28.35 G). LEAD AUTOMOBILE
ALLOY WHEEL BALANCE WEIGHT.
3. INSTALL WEIGHT, RIVETS AND WASHERS WITH PRIMER HORIZONTAL STABILIZER/VERTICAL
4. SEAL EDGES WITH SEALANT AFTER INSTALLATION. STABILIZER ATTACHMENT G535000B
Figure 201. Stabilizer TTail Removal and Installation
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535010 Revision 22
MAINTENANCE MANUAL
(6). Check mount holes for elongation.

Special Tools
(7). For repair (Ref. Vertical Stabilizer (Ref. Section 910000)
Repair). Item Nomenclature
ST2014 Angle measuring tool
6. Horizontal Stabilizer and Tip Plate Repair
Consumable Materials Table 201. Horizontal Stabilizer Angle of

(Ref. Section 910000) Incidence
Item Nomenclature Angle Model
CM220 Naphtha aliphatic 8 55 9 25 369D
CM425 Sealing compound 8 55 9 25 369E
7 30 8 00 369FF
(1). Seal gaps/edges between doublers and
stabilizer skin with sealant (CM425). NOTE: It is not necessary to level helicopter
Remove excess sealant with naphtha when establishing horizontal stabilizer
(CM220). angle of incidence.
D If the mast is tilted forward of 0, add H"
(2). Repaint sealed areas. to S".
(3). Make other horizontal stabilizer repairs D If the mast is tilted aft of 0, subtract H"
according to applicable instructions in from S".
Structural Repair Manual.
(1). Remove hub fairing from main rotor
NOTE: Support helicopter at rear jackpoint hub assembly.
when installing horizontal stabilizer.
(2). Measure incidence angle of horizontal
(4). Install horizontal stabilizer (Ref. stabilizer (Ref. Figure 202) using angle
Horizontal Stabilizer and Tip Plate measurement tool (ST2014) at B.L.
Installation). 10.66 inches (27.076 cm) to right (S
RIGHT) and left (S LEFT) of horizontal
7. Vertical Stabilizer Repair stabilizer centerline. If angles S RIGHT
and S LEFT differ by more than one
degree, replace horizontal stabilizer.
(Ref. Section 910000) (3). Measure inclination of top of main rotor
Item Nomenclature hub (Ref. Figure 203). Record as angle
CM418 Cement, epoxy H.
(4). Compute average of angles S RIGHT
(1). For allowable repairs and additional and S LEFT. Record results as angle S.
inspection criteria, Ref. Structural
(5). (D/E Only) Determine incidence of
Repair Manual.
stabilizer by adding angles H and S. If
(2). Replace damaged or worn seals; bond H plus S is between 8 degrees 55
replacement seal with cement (CM418). minutes and 9 degrees 25 minutes,
angle of incidence is correct.
(3). Replace damaged, worn or missing
grommets. (6). (FF Only) Determine incidence of
stabilizer by adding angles H and S. If
(4). Install vertical stabilizer (Ref. Vertical H plus S is between 7 degrees 30
Stabilizer Installation). minutes and 8 degrees 00 minutes,
angle of incidence is correct.
8. Angle of Incidence Measurement
(7). If angle of incidence is not acceptable
(Ref. Figure 202 and Figure 203) (Ref. Angle of Incidence Adjustment).
Page 204
Revision 37 535010
MAINTENANCE MANUAL
(8). Install hub fairing onto main rotor hub (1). Temporarily apply one ounce tab weight
assembly. to upper right trailing edge of the right
tab using tape.
9. Angle of Incidence Adjustment
(2). Locate weight spanwise to the point of
(1). Remove bolts and washers attaching observed maximum amplitude vibra-
horizontal stabilizer to vertical stabiliz- tion.
er fitting.
NOTE: Tab weight can be made from commer-
Do not add more than two wash- cial automobile alloy wheel balance weight
CAUTION ers under each boss. (0.100 x 0.75 x 2.00 inch).
(2). Lift horizontal stabilizer and add equal (3). Run engine at 102% 105% N2 and
number of AN960PD416L washers observe horizontal stabilizer tab,
under each of two front, or each of two weight may be moved inboard or
rear bosses. outboard on tab depending on response.
(3). Install horizontal stabilizer with (4). If needed, a one ounce weight may also
washers and bolts. be installed on left tab.
(4). Torque bolts to 90 110 inchpounds (5). A maximum of two ounces may be
(10.17 12.43 Nm). installed on each tab.
(5). Repeat angle of incidence measurement
(6). Once correct position and amount of
(Ref. Angle of Incidence Measurement).
weight has been established, install
weight(s) as follows:
10. Horizontal Stabilizer Tab Weight
Installation (a). Cleco weight in place on stabilizer.
Consumable Materials (b). Drill two #31 holes through each

(Ref. Section 910000) weight and stabilizer.
Item Nomenclature
(c). Remove weight and deburr holes;
CM318 Primer touch up stabilizer holes with primer
CM425 Sealing compound (CM318).
(d). Install weight, rivets and washers

(Ref. Figure 201) Installation of tab weight is with wet primer.
optional on the 421087 505 horizontal
stabilizer if difficulty in tail rotor balance and (e). Seal mating edges of weight with
horizontal stabilizer tab resonance vibration is sealing compound (CM425).
encountered (Ref. Sec. 182000, Horizontal
Stabilizer Tuning). (7). Touch up with paint to match.
Table 202. Troubleshooting Tailboom and Tail Surfaces

High frequency vibration. Loose vertical stabilizer. Retorque bolts to 190 220
NOTE: High frequency vibrations in Loose horizontal stabilizer. Retorque nuts to 90 110
helicopter can be caused by inchpounds (10.17 12.43 Nm).
components in other systems (Ref.
Chap. 63, 64 and 71). Check angle of incidence, (Ref. Angle
of Incidence Measurement).
Page 205
535010 Revision 37
MAINTENANCE MANUAL
S LEFT S RIGHT HORIZONTAL

STABILIZER
B.L. 10.66 INCH B.L. 10.66 INCH

(27.076 CM) (27.076 CM)
NOTE 2.030 INCH
13.850 INCH (5.1562 CM)
(35.179 CM)
0.50 INCH (12.7 MM) 0.50 INCH

RADIUS (3 PLACES) (12.7 MM)
1.090 INCH (2.769 CM)
1.575 INCH (4.0005 CM)

CHORD PLANE
OML SKIN AT
STABILIZER STA. 10.66
14.015 INCH
(35.598 CM)
NOTE:
TOOL FUNCTION TO CHECK STABILIZER INCIDENCE. G535001B
Figure 202. Horizontal Stabilizer Incidence Angle Measuring Tool
HORIZONTAL STAB.
TOP OF M/R STAB. INCIDENCE CHORD PLANE
HUB PLANE ANGLE I
AVERAGE STAB. INCLINATION
HUB INCLINATION ANGLE H ANGLE S AVERAGE
CL
GROUND LEVEL PLANE
MAST
G535002
Figure 203. Establishing Horizontal Stabilizer Angle of Incidence
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Revision 40 535010
MAINTENANCE MANUAL
TOP OF RIB 0.250 INCH

369D23608 (6.35 MM)
0.000
0.030 INCH
+0.010
(0.000)
(0.762 MM)
VIEW (+0.254)
TOP OF RIB
369D23609 CL
0.000
0.030 INCH
+0.010
(0.000)
(0.762 MM)
VIEW (+0.254)
SEALANT TO BE APPLIED
AROUND ELECTRICAL
SEALANT (NONHARDENING), EDGES AND CONDUIT
TOOLING HOLES, EXCEPT DRAIN HOLES RTV
DRAIN HOLE 0.60 INCH

(1.524 MM) DIAMETER
THRU SEALANT SHOULD
NOT COVER DRAIN HOLE
TOOLING HOLES
DRAIN HOLE 0.60 INCH (1.524 MM)
DIAMETER THRU SEALANT SHOULD 369D23600 VERTICAL STABI-
NOT COVER DRAIN HOLE LIZER ASSEMBLY
VIEW
G535004A
Figure 204. Sealing Vertical Stabilizer (0003D 0286D)

535010 Revision 19
MAINTENANCE MANUAL
Section
535030
Stabilizer (500/600N)
MAINTENANCE MANUAL
STABILIZER
1. Stabilizers Description a hollow core spar, retainer fittings and
nonstructural leading and trailing edges.
The tail surfaces consist of two verticals and a
horizontal stabilizer. The tail surfaces (empen- The differences on the 600N are that the
nage) stabilize the helicopter and maintain it vertical stabilizers are slightly longer, the skin
in a relatively contain level attitude and is thicker and on standard 600N helicopters,
heading during autorotation and forward are both controlled by the directional control
flight. pedals. The lower vertical stabilizer angle of
attack is eight degrees clockwise relative to the
A. Horizontal Stabilizer Description upper vertical stabilizer. Refer to Section
672030 for flight controls linkage details.
The horizontal stabilizer is constructed of
laminated fiber glass composite ribs and skin, The left vertical stabilizer is mounted to the
bonded to a formed graphite composite spar. horizontal on a torque tube fitting assembly
The horizontal stabilizer includes a nonstruc- and has approximately 6.5 inches (16.51 cm) of
tural leading and trailing edges. hollow core travel.
spar, sparbox fittings, access panels, torque
tubes, bellcranks and control rods. On the 500N and S.A.S. equipped 600N, the
right vertical stabilizer, also mounted on a
On the 500N and optional on the 600N, a torque tube, is controlled by the stability
stability augmentation system (S.A.S.) is augmentation system. From the fully extended
attached to the righthand vertical stabilizer, to the fully retracted position on the S.A.S.
the early 600N does not have a S.A.S system. actuator, the tip of the right vertical stabilizer
trailing edge will travel a minimum of 2.70
The horizontal stabilizer mounts atop the inches (6.86 cm). The amount of travel is
tailboom. Four eye bolts from the horizontal determine by the S.A.S. computer and gyro.
attach to clevis attachment points on the
tailboom. Access plates are attached to the NOTE: The antitorque control system must be
ends caps of the horizontal stabilizer and at rerigged immediately after removal or re-
center line for access to the control rods, S.A.S. placement of control rods, linkages, and
and bellcranks. Two control rods, S.A.S. and components or if helicopter operation re-
bellcranks are routed in the center aft of the veals a rigging deficiency.
sparbox. The angle of incidence of the horizon-
2. Vertical Stabilizer Replacement
tal stabilizer is preset at 2. An anticollision
light is mounted in the top center of the (Ref. Figure 201, Figure 202)
stabilizer. Position lighting provisions are
provided on both ends of the stabilizers. A. Vertical Upper and Lower Stabilizer
Removal
On the 600N without S.A.S., gurney flaps were
added to the trailing edge of the horizontal for (1). Remove nuts, washers, and bolts.
the purpose of increasing lift without increas- Remove by lifting vertical stabilizer off
ing the stabilizer area or weight. torque tube.
Refer to Section 964000 for information on B. Vertical Upper and Lower Stabilizer
exterior lights and Section 672030 for Installation
rigging requirements. (1). Installation with Standard Hardware:
B. Vertical Stabilizers Description Do not overtorque nut. Over
CAUTION torquing nut can crack vertical
The vertical stabilizers (upper and lower) are stabilizer fitting.
constructed of laminated fiber glass composite
ribs and skin, bonded to a formed fiberglass (a). Install stabilizer onto torque tube
composite spar. The vertical stabilizers include fittings.
Page 201
535030 Revision 42
MAINTENANCE MANUAL
(b). Install bolts, washers and nuts. NOTE: Horizontal stabilizer can be removed
Torque to 30 40 inchpounds with vertical stabilizers installed. Support
(3.39 4.52 Nm) plus drag torque. stabilizer during removal.
(2). Installation with Expandable Bolts: A. Horizontal Stabilizer Removal
Do not overtorque nut. Over (1). Remove seven screws securing center
CAUTION torquing nut can crack vertical access plate to horizontal stabilizer.
stabilizer fitting. (2). Disconnect position light electrical
interconnect.
(a). Install bolt with washer under bolt
head and thick washer under nut. (3). On 500N, disconnect S.A.S. electrical
interconnect.
NOTE:
(4). Remove cotter pin, nut, washer and bolt
D Do not remove any expanding elements from center bellcrank shaft. Index mark
from bolt. bellcrank with grease pencil in relation-
D If 600N20125 spacers are not present, ship to shaft. Disconnect bellcrank.
up to two spacers may be added to achieve
proper installation. (5). Remove nuts, washers and expandable
bolts securing horizontal stabilizer to
(b). Remove one (1) or two (2) tailboom attachment clevis fittings.
600N20125 spacers, as required) to Remove horizontal stabilizer.
obtain 0.0050.035 inch (0.1270.889
B. Horizontal Stabilizer Installation
mm) gap between the washers and
the vertical stabilizer, equal on each NOTE: When installing horizontal stabilizer it
side. may be necessary to loosen eye bolts and
nuts to align with clevises, if so, install
(c). Install nut and note drag torque. mounting expandable bolts first and torque
per step (2). below, then torque clevis nuts to
(d). Perform a break in cycle by torquing 80 120 inchpounds (9.04 13.56 Nm).
the nut to 20 25 inchpounds
(2.26 2.82 Nm) plus drag torque. (1). Position horizontal stabilizer on
tailboom attach fittings.
(e). Back off nut until bolt moves freely
in hole. (2). Install expandable bolts, washers and
nut. Torque to 30 40 inchpounds
(f). Torque nut to 20 inchpounds (2.26 (3.39 4.52 Nm). Install cotter pin.
Nm) plus drag torque.
(3). Connect position light/strobe light
(g). Check for equal gap of 0.0050.035 electrical connector.
inch (0.1270.889 mm) between the
(4). On 500N, connect S.A.S. electrical
washers and the vertical stabilizer.
interconnect.
NOTE: NAS1149C0332R or NAS1149C0363R When installing bellcrank on
washers may be added under the nut for ad- CAUTION center bellcrank shaft it is possi-
equate cotter pin engagement. ble to be one spline tooth off in either direc-
tion, install bellcrank centered on shaft
(h). If necessary, tighten nut until cotter
(Ref. Sec. 6720 30).
pin hole aligns with castillation in
nut. (5). Connect bellcrank to center bellcrank
shaft and install bolt, washers and nut.
(i). Install cotter pin. Torque nut to 30 40 inchpounds
(3.39 4.52 Nm) and install cotter pin.
3. Horizontal Stabilizer Replacement
(6). Install center access plate with seven
(Ref. Figure 201 and Figure 202) screws and washers.
Page 202
Revision 42 535030
MAINTENANCE MANUAL
VERTICAL
STABILIZER
(UPPER)
NUT
(NOTE 2)
TRIM TAB
(NOTE 1)
500N TAILBOOM
SHOWN
NUT
(NOTE 2)
VERTICAL
STABILIZER
(LOWER)
WASHER WASHER
BOLT
CENTER
BELLCRANK
SHAFT
TORQUE TUBE
HOUSING
NOTE 4
BELLCRANK CENTER BELLCRANK SHAFT
G5350031B
Figure 201. Stabilizer Installation with YSAS (Sheet 1 of 2)
Page 203
535030 Revision 33
MAINTENANCE MANUAL
YSAS ACTUATOR
(500N, AND 600N WITH YSAS)
CENTER ACCESS
PLATE
HORIZONTAL
STABILIZER
EYEBOLT END TIP

ACCESS
COVER TORQUE
TUBE
WASHER
SPACER
(NOTE 3)
TAILBOOM BEARING RACE

ATTACH
FITTING
BELLCRANK
BUSHING NOTE 4
COTTER PIN
NUT
NOTES:
1. TYPICAL LEFT AND RIGHT STABILIZERS (500/600N).
2. TORQUE 30 40 INCHPOUNDS (3.39 4.52 NM) PLUS DRAG TORQUE.
3. SPACERS INSTALLED ON AFT BOSS ONLY.
4. OPENING IN BELLCRANK ALWAYS FACES OUTBOARD (LH AND RH SIDES). G5350032F
Figure 201. Stabilizer Installation with YSAS (Sheet 2 of 2)
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Revision 33 535030
MAINTENANCE MANUAL
4. Horizontal Stabilizer Eye Bolt (2). Install control tubes and bellcranks as
Replacement required, safety wire or cotter pin.
A. Horizontal Stabilizer Eye Bolt Removal (3). Install center access plate with seven
screws and washers.
(1). Remove horizontal stabilizer.
6. Vertical Stabilizer Inspection
(2). Remove eye bolts by holding the flat
surface of eye bolt with a wrench and (Ref. Figure 201 and Figure 202)
removing nut. (1). Inspect skin for cracks, bonding
separation, delamanation and obvious
B. Horizontal Stabilizer Eye Bolt Installation damage.
(1). Install eye bolts in horizontal stabilizer, (2). Inspect stabilizer for freedom of
the short eye bolts in the forward holes movement through pedal travel range,
and the longer eye bolts with spacer to check for clearance between vertical to
the aft holes of horizontal stabilizer. horizontal.
(2). Torque eye bolts to 80 120 inch (3). Check mounting fitting holes for
pounds (9.04 13.56 Nm) plus drag elongation.
torque.
NOTE: Internal stabilizer fitting may display
(3). Install horizontal stabilizer. cracking after installation of expandable
bolts. This cracking, internal fitting only, is
5. Horizontal/Vertical Stabilizer Control Tube acceptable for continued service. Cracking
and Bellcrank Replacement of the external skin from the mounting bolt
holes is unacceptable and stabilizer must be
(Ref. Figure 201 and Figure 202) removed from service and scrapped.
A. Horizontal/Vertical Stabilizer Control Tube 7. Vertical Stabilizer Repair

and Bellcrank Removal Refer to MDHI Field Service Representative.
(1). Remove horizontal stabilizer end tip 8. Horizontal Stabilizer Inspection
covers and center access cover for
access to bellcranks and control tubes. (1). Inspect skin for cracks, bonding
separation, delamination and obvious
(2). Remove cotter pin, nut, washer and bolt damage.
from center bellcrank shaft. Index mark
bellcrank with grease pencil in relation- (2). Inspect mounting fitting and attach-
ship to shaft. Disconnect bellcrank. ment hardware for condition.
(3). Disconnect control tube from vertical (3). Inspect center access panel and nut
stabilizer torque tube bellcrank. plate fasteners for condition, end tip
Remove controls from horizontal plate access covers and position lights
stabilizer as required for maintenance. for condition.
(4). Inspect vertical stabilizer torques tubes
B. Horizontal/Vertical Stabilizer Control Tube for excessive axial and radial move-
and Bellcrank Installation ment, 0.010 inch (0.254 mm) axial end
play maximum allowable.
Refer to adjustment and test control rigging
during installation. (5). Inspect torque tube bushings for wear
and security.
(1). Connect bellcrank to center bellcrank
shaft and install bolt, washers and nut. (6). If the bushings are not bonded to the
Torque bolt to standard aircraft torque horizontal stabilizer, rework Vertical
values and install cotter pin. Stabilizer Torque Tube Bushings.
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535030 Revision 40
MAINTENANCE MANUAL
9. Vertical Stabilizer Torque Tube (2). Apply one layer of teflon tape (CM726)
Replacement to threads of torque tube prior to
installing locknut.
A. Vertical Stabilizer Torque Tube Removal
(3). Install locknut, hand tighten and adjust
(1). Remove vertical stabilizers (Ref. to a 0.0050.010 inch (0.1270.254 mm)
Vertical Stabilizer Replacement). gap; Install cotter pin.
(2). Remove horizontal tip plate access NOTE: When installing the bellcrank, opening
cover and disconnect YSAS torque tube in bellcrank must face outboard.
(if installed) from vertical stabilizer (4). Install bellcrank, with opening facing
bellcrank. outboard, on torque tube and install
(3). Remove bellcrank from torque tube by expandable bolt; Torque to 30 40
removing expandable bolt. inchpounds (3.39 4.52 Nm) plus
drag torque; Install cotter pin.
(4). Remove cotter pin, locknut and bushing (5). Connect YSAS actuator to vertical
from torque tube. Remove torque tube stabilizer torque tube bellcrank. Torque
by lifting upward. nut to 30 40 inchpounds (3.39
4.52 Nm) and install cotter pin.
B. Vertical Stabilizer Torque Tube
Installation (6). Install end plate access covers.
(1). Slide torque tube from the top thru the (7). Install vertical stabilizer (Ref. Vertical
horizontal stabilizer. Stabilizer Replacement).
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Revision 40 535030
MAINTENANCE MANUAL
GURNEY FLAPS
RIGHT
CONTROL ROD
AFT
CONTROL ROD
NOTE 1
NOTE:
1. EXTRA WASHER BETWEEN RADIUS BLOCK
LEFT AND SPACER.
CONTROL ROD NOTE 2 2. OPENING IN BELLCRANK ALWAYS FACES
OUTBOARD (LH AND RH SIDES).
EARLY 600N SHOWN G5350033B
Figure 202. Stabilizer Installation without YSAS
Page 207
535030 Revision 40
MAINTENANCE MANUAL
VERTICAL STABILIZER TORQUE TUBE
EXPANDABLE
ELEMENTS NON EXPANDABLE
ELEMENT
THIN WASHER
THIN WASHER
THICK EXPANDABLE
WASHER SPACERS (2) ELEMENTS
EXPANDABLE DIAMETER
BOLT INSTALLATION
WASHER
(OPTIONAL)
NUT
COTTER PIN
THICK WASHER
WASHER
SPACERS BOLT
WASHER
(OPTIONAL)
COTTER NUT
PIN
THICK WASHER
WASHER
SPACERS BOLT MAX. DIA. O.254 IN. (6.4516 MM)
(8 PLCS) EACH TORQUE TUBE
TORQUE TUBE
NOTE:
THE BOLT, WASHER, THICK WASHER, SPACERS AND NUT ARE
COMPONENTS OF THE EXPANDABLE DIAMETER BOLT ASSEMBLY. 535007
Figure 203. Vertical Stabilizer Installation with Expandable Bolts
Page 208
Revision 40 535030
MAINTENANCE MANUAL
10. Horizontal Stabilizer Repair 4.52 Nm) plus drag torque; Install
cotter pin.
Refer to MDHI Field Service Representative.
(10). Connect YSAS actuator to vertical
11. Vertical Stabilizer Torque Tube and/or stabilizer torque tube bellcrank. Torque
Bushing Replacement (NonBonded nut to 30 40 inchpounds (3.39
Bushings) 4.52 Nm) and install cotter pin.
(Ref. Figure 201) The following procedure is for (11). Install end plate access covers.
replacing the early style (nonbonded) torque (12). Install vertical stabilizer (Ref. Vertical
tube bushings. Stabilizer Replacement).
12. Vertical Stabilizer Torque Tube and/or
Bushing Replacement (Bonded Bushings)
Item Nomenclature (Ref. Figure 201) The following procedure is for
CM726 Tape, teflon replacing the current style (bonded) torque
tube bushings.
(1). Remove vertical stabilizers (Ref.

Vertical Stabilizer Replacement).
(2). Remove horizontal tip plate access Item Nomenclature
cover and disconnect YSAS torque tube CM222 1,1,1Trichloroethane
(if installed) from vertical stabilizer CM402 Adhesive
bellcrank. CM726 Tape, teflon
(3). Remove bellcrank from torque tube by CM802 Abrasive cloth, aluminum oxide
removing expandable bolt.
(1). Remove vertical stabilizers (Ref.
(4). Remove cotter pin, locknut and bushing Vertical Stabilizer Replacement).
from torque tube. Remove torque tube
by lifting upward. (2). Remove horizontal tip plate access
cover and disconnect YSAS torque tube
(5). Remove bushing from bearing race of (if installed) from vertical stabilizer
torque tube. bellcrank.
(6). Install one bushing on bearing race of (3). Remove bellcrank from torque tube by
torque tube and insert torque tube removing expandable bolt.
through fitting of horizontal stabilizer
from the top downward. (4). Remove cotter pin, locknut and bushing
from torque tube. Remove torque tube
(7). Apply one layer of teflon tape (CM726) by lifting upward.
to threads of torque tube prior to
In the following steps, care must
installing locknut. CAUTION be taken to not damage the fi-
(8). Install bushing and locknut, hand bers of the horizontal stabilizer.
tighten locknut and adjust to a (5). Remove bushing(s) from horizontal
0.0050.010 inch (0.1270.254 mm) stabilizer by gently working a sharp
gap; Install cotter pin. scraper between bushing and stabilizer.
NOTE: Ensure shouldered bushings are (6). Sand excess sealant from horizontal
installed in bellcrank. stabilizer taking care not to disturb the
composite fibers of the stabilizer.
(9). Install bellcrank on torque tube and
install expandable bolt and washers; (7). Clean faying surfaces of horizontal
Torque to 30 40 inchpounds (3.39 stabilizer, where bushings are to be
Page 209
535030 Revision 40
MAINTENANCE MANUAL
bonded, with 1,1,1trichloroethane 13. Vertical Stabilizer Torque Tube Bushing

(CM222). Rework (NonBonded Bushings to
Bonded Bushings)
(8). Wipe dry using a clean dry rag and
then allow to air dry for 15 minutes. (Ref. Figure 201) The following procedure is for
converting the vertical stabilizer torque tube to
(9). Lightly abrade the faying surface of the the current 500N39803 bushings,
new bushings with abrasive cloth 500N39703 locknuts and MS24665361
(CM802) until all gloss is removed. cotter pins.
Wipe clean with 1,1,1trichloroethane.
(10). Wipe dry using a clean dry rag and Consumable Materials
then allow to air dry for 15 minutes. (Ref. Section 910000)
Item Nomenclature
(11). Mix adhesive (CM402) according to CM222 1,1,1Trichloroethane
manufacturers instructions. Apply
CM402 Adhesive
adhesive within 2 hours of cleaning.
CM726 Tape, teflon
(12). Apply a thin uniform layer of adhesive CM802 Abrasive cloth, aluminum oxide
to faying surfaces.
Do not apply too much pressure, (1). Remove vertical stabilizers (Ref.
CAUTION damage to horizontal stabilizer Vertical Stabilizer Replacement).
may occur.
(2). Remove cotter pins, locknuts and
(13). Press the faying surfaces firmly bushings, and scrap. Remove torque
together and maintain contact pressure tube by lifting upward. Remove bushing
or apply 50 psi (3.45 kPa) maximum for and scrap.
24 hours at ambient temperature.
(3). Clean faying surfaces of horizontal
(14). Using 1,1,1trichloroethane, clean stabilizer, where bushings are to be
excess adhesive from parts before bonded, with 1,1,1trichloroethane
adhesive has had time to cure. (CM222).
(15). Slide torque tube from the top thru the (4). Wipe dry using a clean dry rag and
horizontal stabilizer. then allow to air dry for 15 minutes.
(5). Lightly abrade the faying surface of the
(16). Apply one layer of teflon tape (CM726)
new bushings with abrasive cloth
to threads of torque tube prior to
(CM802) until all gloss is removed.
installing locknut.
Wipe clean with 1,1,1trichloroethane.
(17). Install locknut, hand tighten and adjust (6). Wipe dry using a clean dry rag and
to a 0.0050.010 inch (0.1270.254 mm) then allow to air dry for 15 minutes.
gap; Install cotter pin.
(7). Mix adhesive (CM402) according to
(18). Install bellcrank on torque tube and manufacturers instructions. Apply
install expandable bolt; Torque to 30 adhesive within 2 hours of cleaning.
40 inchpounds (3.39 4.52 Nm)
plus drag torque; Install cotter pin. (8). Apply a thin uniform layer of adhesive
to faying surfaces.
(19). Connect YSAS actuator to vertical
stabilizer torque tube bellcrank. Torque Do not apply too much pressure,
CAUTION damage to horizontal stabilizer
nut to 30 40 inchpounds (3.39
4.52 Nm) and install cotter pin. may occur.
(20). Install end plate access covers. (9). Press the faying surfaces firmly
together and maintain contact pressure
(21). Install vertical stabilizer (Ref. Vertical or apply 50 psi (3.45 kPa) maximum for
Stabilizer Replacement). 24 hours at ambient temperature.
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Revision 40 535030
MAINTENANCE MANUAL
(10). Using 1,1,1trichloroethane, clean (a). Locate a steel plate of approximately

excess adhesive from parts before 0.250 inch (6.35 mm) thickness.
adhesive has had time to cure.
(b). Drill a 1.510 inch (38.3540 mm) hole
(11). Slide torque tube from the top thru the in the plate.
horizontal stabilizer. (c). Deburr edges of hole to prevent
(12). Apply one layer of teflon tape (CM726) damage to torque tube.
to new 500N39703 locknut. (d). Apply tape (CM730) to tool to prevent
damage to bearing race.
(13). Install locknut, hand tighten and adjust
to a 0.0050.010 inch (0.1270.254 mm) (4). Insert torque tube through the removal
gap; Install MS24665361 cotter pin. tool and install on arbor press.
(14). Install bellcrank on torque tube and In the following steps, care must
CAUTION be taken to not damage the hori-
install expandable bolt; Torque to 30
40 inchpounds (3.39 4.52 Nm) zontal stabilizer torque tube.
plus drag torque; Install cotter pin. (5). Place suitable device over torque tube
(15). Install end plate access covers. end to protect tube from damage from
arbor press.
(16). Install vertical stabilizer (Ref. Vertical (6). Remove bearing from the torque tube
Stabilizer Replacement). by gently pressing torque tube through
the removal tool.
14. Vertical Stabilizer Torque Tube Bearing
Race Replacement (7). Using solvent (CM234), clean primer
residue from torque tube.
removal of the bearing race from the vertical (8). Inspect torque tube for damage to
stabilizer torque tube. Some special tools will bearing race contact surface.
need to be manufactured for this procedure. (9). Fabricate the following tool for bearing
race installation.
Consumable Materials (a). Locate a steel plate of approximately
(Ref. Section 910000) 0.250 inch (6.35 mm) thickness.
Item Nomenclature
CM234 Solvent, drycleaning (b). Drill a 1.390 inch (35.306 mm) hole
in the plate.
CM318 Primer
CM730 Tape, duct (c). Deburr edges of hole to prevent
damage to torque tube.
Special Tools (d). Apply tape (CM730) to tool to prevent
(Ref. Section 910000) damage to bearing race.
Item Nomenclature
N/A Arbor press (10). Insert bearing race into tool and mount
on arbor press.
(11). Coat torque tube bearing race mating
(1). Remove vertical stabilizers (Ref. surface with primer (CM318).
Vertical Stabilizer Replacement).
In the following steps, care must
(2). Remove vertical stabilizer torque tubes CAUTION be taken to not damage the the
(Ref. Vertical Stabilizer Torque Tube horizontal stabilizer torque tube.
Replacement).
(12). Place suitable device over torque tube
(3). Fabricate the following tool for bearing end to protect tube from damage from
race removal. arbor press.
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535030 Revision 40
MAINTENANCE MANUAL
In the following step, ensure ensure no warpage occurred during

CAUTION bearing race is not cocked on installation.
torque tube, this will cause nonrepairable
damage to bearing race and torque tube. (15). Reinstall vertical stabilizer torque
tubes (Ref. Vertical Stabilizer Torque
Tube Replacement).
(13). While primer is wet, press torque tube
down through the bearing race until (16). Reinstall vertical stabilizers (Ref.
bearing race is tight against flange on Vertical Stabilizer Replacement).
torque tube.
15. Stabilizer Troubleshooting
(14). Inspect bearing race flanged surface to (Ref. Table 201)
Table 201. Troubleshooting Tailboom and Tail Surfaces
High frequency vibration Fan assembly out of balance Rebalance fan assembly.
Loose fan blades Replace and rebalance fan assy.
Loose bolts/nuts on Horizontal or Inspect mounting hardware; adjust or
Vertical stabilizer replace as necessary.
NOTE: High frequency vibrations in helicopter can be caused by components in other systems (Ref. Sec.
640000, 632510, 632530 and 710000).
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Chapter
62
Main Rotor
MAINTENANCE MANUAL
TABLE OF CONTENTS
620000 Main Rotor (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Main Rotor System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Main Rotor System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Main Rotor Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 102
621000 Main Rotor Blade (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Blade General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Blade Leading Edge Erosion Protection General . . . . . . . . . . . . . . . 401
2. Main Rotor Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Main Rotor Blade and Damper Attach Pin Installation and Adjustment . . . . . . . . 401
Figure 401. Main Rotor Blade Attachment and Outboard End . . . . . . . . . . . . . 403
1. Main Rotor Blade Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Main Rotor Blade Damage and Repair Limits Nicks,
Scratches, Gouges and Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
2. Main Rotor Blade and Damper Attach Pin Inspection and Corrosion
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
3. Main Rotor Blade and Damper Attach Pin Disassembly and Special
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4. Main Rotor Blade Forward Tip Cap Inspection and Corrosion Protection . . . . . . . . 605
5. Main Rotor Blade Upper and Lower Root Fitting Attach Lug and LeadLag
Link Attach Lug Inspection (25 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Figure 602. Main Rotor Blade Damage Limits for Dents and Depressions . . . . 606
Figure 603. Main Rotor Blade Attach Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
6. Main Rotor Blade Upper and Lower Root Fitting, Attach Lug and LeadLag
Link Attach Lug Inspection (100 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
7. Main Rotor Blade Leading Edge Abrasion Strip Check . . . . . . . . . . . . . . . . . . . . . . . . 610
8. Main Rotor Blade Torque Event Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Figure 604. Main Rotor Blade Root Fitting, Attach Lugs and LeadLag Link
Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Figure 605. Application of Slippage Mark to Main Rotor Blade Bushings and
Root Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Blade Repair (Nicks, Scratches and Wear Spots) . . . . . . . . . . . . . . . . . . . 801
2. Main Rotor Blade Repair (Dents, Depressions and Erosion) . . . . . . . . . . . . . . . . . . . . 801
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3. Trim Tab Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Forward Tip Cap Threaded Insert Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801. Main Rotor Blade Trailing Edge Weight Rework. . . . . . . . . . . . . . . . . 803
5. Loose Balance Weight Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
6. Loose Trailing Edge Weight Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
7. Loose or Missing Rivets or Aft Tip Cap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 802. Repair and Removal of Trim Tab, Main Rotor Blade . . . . . . . . . . . . . 805
Figure 803. Bearing Replacement Main Rotor Blade Damper Attach
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8. Damper Attach Blade Fitting Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 806
9. Leading Edge Protective Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 804. Installation/Replacement of Stainless Steel Abrasion Tape
(Main Rotor Blade Leading Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Figure 805. Installation/Replacement of Double Layer Abrasion Tape
(369D21100505 and 509 Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . 808
10. Leading Edge Abrasion Strip Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
11. Tip Cap Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Figure 806. Main Rotor Blade Abrasion Strip and Tip Cap Sealing . . . . . . . . . . . 810
12. Main Rotor Blade Protective Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
A. Stainless Steel Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
622000 Main Rotor Hub (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Hub General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Rotor Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pulling Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Main Rotor Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Main Rotor Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Rotor Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Main Rotor Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Main Rotor Damper Nominal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
1. Main Rotor Hub Balancing General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Main Rotor Blade Phasing Check and/or Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Main Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
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Figure 601. Strap Pack Lamination Exploded View . . . . . . . . . . . . . . . . . . . . . . . 602
4. LeadLag Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Main Rotor Strap Pack Lamination Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2) . . . . . . . . . . . . . . . . 605
Table 601. Strap Pack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
6. Main Rotor Hub Droop Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
7. Main Rotor Damper and Attachments Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
8. Main Rotor Damper Weight Loading and Extension Check . . . . . . . . . . . . . . . . . . . . 609
Figure 603. Periodic Check of Main Rotor Damper Assembly . . . . . . . . . . . . . . . . 610
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Retention Strap Pack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Pitch Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Unbushed Outboard Clevis Lug Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Pitch Control Bearing Housing Assembly, Spacer or Striker Strip
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
5. Pitch Control Bearing Housing Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
6. Pitch Control Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 802. Main Rotor Hub Components Repair and Installation
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
7. LeadLag Link Blade Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 803. Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
8. Damper Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
9. LeadLag Bolt Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
10. Pitch Control Bearing Pivot Pin Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . 810
11. Droop Stop Roller Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
12. Droop Stop Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
13. Droop Stop Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
14. Droop Stop Follower (THead) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
15. Droop Stop Plunger Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . 812
16. Main Rotor Hub Droop Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Figure 804. Main Rotor Hub Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
17. Main Rotor Hub Tapered Bearing Grease Repack, Inspection and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
18. Main Rotor Hub Scissors Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . 815
Figure 805. Main Rotor Hub Cross Section (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . 817
Figure 806. Tapered Bearing Tools Main Rotor Hub (Sheet 1 of 2) . . . . . . . . . . 819
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622060 Main Rotor Hub (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Main Rotor Hub General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Rotor Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pulling Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Main Rotor Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Main Rotor Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Rotor Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Main Rotor Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Main Rotor Damper Nominal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
1. Main Rotor System Balancing General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Main Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Strap Pack Lamination Exploded View . . . . . . . . . . . . . . . . . . . . . . . 602
3. LeadLag Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Main Rotor Strap Pack Lamination Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2) . . . . . . . . . . . . . . . . 604
Table 601. Strap Pack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
5. Main Rotor Hub Droop Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
6. Main Rotor Damper and Attachments Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
7. Main Rotor Damper Weight Loading and Extension Check . . . . . . . . . . . . . . . . . . . . 609
Figure 603. Periodic Check of Main Rotor Damper Assembly . . . . . . . . . . . . . . . . 610
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Retention Strap Pack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Pitch Control Bearing Housing Assembly, Spacer or Striker Strip
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3. LeadLag Link Blade Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802. Main Rotor Hub Components Repair and Installation . . . . . . . . . . . 803
4. LeadLag Bolt Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
5. Pitch Control Bearing Pivot Pin Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . 804
6. Droop Stop Roller Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
7. Droop Stop Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8. Droop Stop Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
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9. Droop Stop Follower (THead) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 803. Droop Stop Ring Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . 806
10. Droop Stop Plunger Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . 807
11. Main Rotor Hub Droop Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
12. Main Rotor Hub Tapered Bearing Grease Repack, Inspection and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 804. Tapered Bearing Tools Main Rotor Hub (Sheet 1 of 2) . . . . . . . . . . 809
13. Main Rotor Hub Upper Bearing Grease Repack, Inspection and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
14. Main Rotor Hub Scissors Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . 813
Figure 805. Main Rotor Hub Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
623000 Swashplate and Mixer (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Swashplate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Mixer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Mixer Controls Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Mixer Controls Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pitch Control Rods and Swashplate Scissors Installation . . . . . . . 402
B. Mixer Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Mixer Controls Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Scissors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
6. Scissors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Scissors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Scissors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
7. Scissors Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
8. Pitch Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9. Pitch Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Pitch Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Pitch Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
10. Counterweight and Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Swashplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Mixer Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Page v
MAINTENANCE MANUAL

3. Scissors Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Pitch Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Swashplate Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Mixer Controls Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Scissors Bushing and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Scissors Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801. Field Modification 369D2100211 Crank Assembly to
369D2100221 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Installation of 369D2100221 Crank to Hub Lower Shoes . . . . . . . 804
5. Mixer Controls Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 1 of 2) . . . . . . . . . 806
623060 Swashplate and Mixer (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Swashplate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pitch Control Rods and Swashplate Scissors Installation . . . . . . . 402
3. Controls Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Controls Mixer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Controls Mixer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Mixer Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Controls Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Scissors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
6. Scissors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Scissors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Scissors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
7. Scissors Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
8. Pitch Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9. Pitch Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Pitch Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Pitch Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Swashplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Mixer Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Page vi
MAINTENANCE MANUAL

3. Scissors Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Pitch Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Swashplate Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Mixer Controls Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Scissors Bushing and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Page vii
MAINTENANCE MANUAL

Page viii
MAINTENANCE MANUAL
Section
620000
Main Rotor
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR
FAULT ISOLATION
1. Main Rotor System General Information NOTE: Unless specifically indicated in the text
and illustrations, information applies to all
NOTE: AutoRotation RPM charts are found in model helicopters. Where information is
Chapter 18. limited to a specific model helicopter or con-
The main rotor located over the helicopter figuration, the text or effectivity block will
centerofgravity provides lift, lateral and indicate.
longitudinal control. The fundamental
components of the rotor are five or six remov- 2. Main Rotor System Troubleshooting
able blades, pitch housings and a hub. Each
articulated blade is controlled through a pitch Sudden onset of excessive
housing and link arrangement which transfers WARNING and/or unusual main rotor
flight control inputs into the rotor blades. vibration should be investigated imme-
Rotor blades, pitch housings and links are diately as to the cause, prior to contin-
secured to the hub by five sets of laminated ued flight. Under no circumstance
steel straps. The collective, stick working should main rotor tracking be at-
through linkages, increases or decreases rotor tempted to correct the problem until a
blade angle affecting helicopter ascent and thorough inspection of the main rotor
descent (collective pitch). Helicopter pitch and blades, hub assembly and strap pack
roll angles are controlled by the cyclic stick. assembly has been performed.
Mixed collective and cyclic control inputs are
simultaneously transferred into the main rotor (1). First determine which major installa-
for coordinated flight control. The four main tion is defective.
equipment groups of the main rotor and
control system are the rotor blades, hub, upper (2). Isolate each linkage installation from
exterior controls, and cyclic and collective others until area of malfunction is
controls in the pilots compartment. located.
(1). Main rotor blades (3). Investigate and determine exact

(Ref. Sec. 621000). location of malfunction.
(2). Main rotor hub (4). Repair or replace defective components.
(Ref. Sec. 622000 and 622060).
(3). Main rotor swashplate and mixer NOTE: First indications of trouble are usually
(Ref. Sec. 623000 and 623060). felt through cyclic or collective controls. Iso-
lation procedures (Ref. Table 101, Sec.
(4). Main rotor flight controls 6710) indicate symptoms detected through
(Ref. Chap. 67). these controls.
Page 101
620000 Revision 20
MAINTENANCE MANUAL
Table 101. Troubleshooting Main Rotor Vibrations

Unusual or excessive vibration. Main rotor blades damaged. Inspect blades
(Ref. Sec. 621000).
Vertical or Lateral vibration. Main rotor hub or hub components Inspect main rotor hub assembly
damaged. (Ref. Sec. 622000/622060).
Inspect strap pack assemblies.
Oneper revolution lateral beat in Defective damper or blade phasing. Check damper nominal adjustment
hover and cruise. May also occur (Ref. Sec. 622000/622060)
on ground during warmup or Replace defective damper.
shutdown.
Fiveperrevolution or Worn pitch control bearings. Replace pitch control bearings

mediumfrequency beat. (Ref. Chap. 67).
Oneper revolution vertical beat. Main rotor blades out of track. Track main rotor blades
Beat may appear throughout (Ref. Sec. 181000/181060).
entire flight regime, becoming
more pronounced at higher
airspeeds.
Lateral feedback (beat) in cyclic Rotor blades out of track. Track main rotor blades
control stick with no longitudinal (Ref. Sec. 181000/181060).
feedback detected.
Oneperrevolution lateral beat, Main rotor blade tip balance weights Check balance weights for security;
continuous. not secure. repair as necessary:
(Ref. Sec. 621000).
Incorrect blade phasing. Check main rotor track and balance

(Ref. Sec. 181000/181060).
High frequency vibrations. Loose or defective component in (Ref. Chaps. 18, 62, 64 and 67)
another system.
Main rotor track and/or balance Play between longitudinal pitch mixer Rebond collective pitch mixer
inconsistant. bellcrank and collective pitch mixer bearings and install shims between
bellcrank. longitudinal pitch mixer bellcrank and
bearings (Ref. Sec. 623000 or
623060).
Page 102
Revision 31 620000
MAINTENANCE MANUAL
Section
621000
Main Rotor Blade
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR BLADE

1. Main Rotor Blade General blades can be reinstalled in same
relative positions.
Each of the main rotor blades are a balanced
airfoil consisting primarily of a wraparound, (4). Slide blade from leadlag links.
aluminum alloy skin bonded to an extruded B. Main Rotor Blade Installation
aluminum alloy spar, an upper root fitting and
a lower root fitting (Ref. Figure 401). Two (Ref. Figure 401)
preset balance weights are installed in the tip
end of each blade. A removable forward tip (1). Position main rotor blade in its
cap, at the outboard end of each blade, is (marked) pitch housing links. Install
replaced with a tracking cap when tracking. blade attaching pins.
Blade trailing edge tab may be bent up or If new blade is to be installed, or
down to compensate for differences in diving or CAUTION if blades are not reinstalled in
climbing characteristics between individual same positions from which removed or are
blades during forward flight. installed on new rotor hub, blade attach
pins must be adjusted. It is also necessary to
A. Main Rotor Blade Leading Edge Erosion track blades.
Protection General
(2). Align damper clevis on fitting of main
Rotor blades produced since 1980 have an 18 rotor blade; install damper attach bolt
inch or 36 inch leading edge abrasion strip to to attach clevis to blade.
reduce wear. Earlier model blades without the
abrasion strip that are used in a highly (3). Remove bladetopitch housing link
abrasive environment should have outer 24 matchmarkings.
inches of each blade (PN 369D21100503 or
507, Ref. Figure 804) or outer 18 inches of 3. Main Rotor Blade and Damper Attach Pin
each blade (PN 369D21100505 or 509, Ref. Installation and Adjustment
Figure 805) leading edge covered equally by Whenever new attach pin is in-
protective tape so blade life is not reduced by CAUTION stalled, main rotor blade is re-
excessive erosion. placed, or rotor hub assembly is replaced,
adjustment is required to ensure that pins
2. Main Rotor Blade Replacement properly fit in mating holes.
A. Main Rotor Blade Removal (1). Check main rotor blade and damper
arm attach pins for cracks, wear and
(Ref. Figure 401) corrosion.
(1). Relieve load on blade attachment points (2). Support blade tip to establish align-
by supporting main rotor blade from ment of holes in blade root fittings and
below. pitch housing leadlag links; install
pin.
(2). Identify blade attaching hardware and NOTE: After final adjustment of main rotor
pins for location (grease pencil, tape, blade and damper attach pins, thread pro-
etc). Detach damper clevis from blade. trusion from adjuster nut of 1/2 to 1 thread
Remove two blade fitting attaching is acceptable if adjuster nut runon torque
pins. is a minimum of 4 inchpounds (0.45
Nm) and attach pin safety latch is securely
(3). If rotor system is not already color latched over adjuster nut.
coded, use masking tape and/or grease
pencil, to mark each blade and its (3). Adjust pin for correct fit by rotating
respective pitch housing links so that small hex nut at end of pin until 25
Page 401
621000 Revision 20
MAINTENANCE MANUAL
35 pounds force (111.2 155.68 N) is (4). At final installation, locking levers of

required to snap safety latch into place both blade root fitting pins should be
over nut. located inboard of (behind) stop springs
NOTE: After adjustment, measure installed of pitch housing leadlag links.
length of pins from face of thrust washer to
outer edge of last bushing, dimension
should be 0.991.04 inch (2.5152.642 cm)
for damper pins and 2.842.89 inches
(7.2147.341 cm) for main rotor blade pins.
Page 402
Revision 20 621000
MAINTENANCE MANUAL
MINIMUM 2THREAD TURNBUCKLE

JAMNUT
PROTRUSION AFTER
FINAL ADJUSTMENT
BOLT
WASHER
WASHER
NUT
JAMNUT
COTTER PIN
JAMNUTS SAFETY WIRED TO

TURNBUCKLE AFTER FINAL
ADJUSTMENT 369D21102 BLADE
DAMPER CLEVIS ATTACHMENT

BLADE ATTACHING
PIN
DAMPER
UPPER ROOT
FITTING
ALTERNATE DAMPER
CLEVIS ATTACH PIN BUSHING
(NOTE 2)
BLADE TAB
LOWER ROOT
FITTING
VENT HOLE
TIP CAP
BLIND RIVET
(NOTE 1) 0.1300.160 IN.
SPAR AND WEIGHT RIVETS

2.62 INCH
(6.655 CM)
AFT TIP CAP FORWARD BALANCE WEIGHT
SCREW THREADED AFT BALANCE
FORWARD INSERT
TIP CAP WEIGHT NOTES:
1. BLIND RIVETS TO BE INSTALLED THRU EACH SIDE OF
369D21100 BLADE ALL BLADES. IF ONE TIP CAP REPLACED OR REPAIRED,
ASSEMBLY BALANCE IS NOT AFFECTED.
2. BUSHING INSTALLED IN EACH OF UPPER AND LOWER
ATTACHMENT LUGS.
G621000A
Figure 401. Main Rotor Blade Attachment and Outboard End

621000 Revision 20
MAINTENANCE MANUAL
MAIN ROTOR BLADE

INSPECTION/CHECK
1. Main Rotor Blade Inspection 90 degrees from spanline are acceptable
without repair. Nicks and gouges not
Special Tools
exceeding 0.003 inch (0.076 mm) depth
are acceptable without repair and to
Item Nomenclature
0.005 inch (0.127 mm) with repair.
N/A Plastic inspection tool (Fabricate from AREA 3: Scratches to 0.005 inch (0.127
0.0010.002 inch (0.0250.051 mm) thick mm) depth if oriented 030 degrees
plastic material) from spanline and to 0.003 inch (0.076
mm) deep if oriented between 3040
degrees from spanline must be re-
(1). Inspect skin for evidence of cracks and moved. No sharp nicks or gouges
holes. Cracks or holes in blade skin requiring more than 0.005 inch (0.127
surface, regardless of location, are mm) removal of skin surface are
cause for rejection of blade. Scratches, permissible.
dents, nicks and other surface defects
in blade skin are limited according to AREA 4: Scratches to 0.003 inch (0.076
(3). below. Use suitable dial indicator to mm) depth if oriented 030 degrees and
check depth of blade dents and to 0.003 inch (0.076 mm) depth if
scratches. oriented between 3090 degrees from
spanline must be removed. No sharp
Repairable limit dimensions in nicks or gouges requiring more than
CAUTION following procedures apply to 0.003 inch (0.076 mm) removal of skin
surfaces that have not been repaired before. surface are permissible.
Be sure that material has not been removed
AREA 5: Scratches exceeding a depth
from damaged areas before determining
of 0.001 inch (0.025 mm) are cause for
that damage depth limit has not been ex-
rejection. Remove scratches to a depth
ceeded. Refer all questionable surface dam-
of 0.001 inch (0.025 mm). Area inside
age not covered by following information to
outboard two root fitting bolt holes
MDHI.
(both upper and lower surfaces) and
(2). (Ref. Figure 601) Limitations for including skin surface adjacent to these
surface scratches, nicks, gouges and bolt holes within radius of 1.00 inch
erosion in seven areas of blade skin are (2.54 cm) from each hole must be free of
described below. Scratches that do not scratches, nicks, or gouges as would be
penetrate clad surface are acceptable detected under 5X magnification
without reword in all areas except (minimum).
AREAS 5 and 8. AREA 6: Scratches to 0.005 inch (0.127
AREA 1: Minor scratches, nicks and mm) depth and oriented 015 degrees
gouges without skin penetrations are from spanline are acceptable without
acceptable without repair. Skin defor- repair. Scratches to 0.005 inch (0.127
mation with holes is cause for replace- mm) depth and oriented from 1530
ment. Blade leading edge erosion may degrees from spanline must be re-
be repaired if skin is not eroded moved. Scratches 0.003 inch (0.076
through. If leading edge skin is eroded mm) deep and oriented from 1530
through, no matter how slightly, blade degrees from spanline are acceptable
must be replaced immediately. without repair. Scratches to 0.003 inch
(0.076 mm) depth and oriented from
AREA 2: Scratches to 0.005 inch (0.127 3090 degrees from spanline must be
mm) depth if oriented 030 degrees repaired. Nicks and gouges not exceed-
from spanline and to 0.003 inch (0.076 ing 0.005 inch (0.127 mm) depth must
mm) depth if oriented between 30 and be repaired. All gouges, nicks, scratches
Page 601
621000 Revision 20
MAINTENANCE MANUAL
and cracks on trailing edge not exceed- acceptable without repair. No repairs
ing 0.030 inch (0.076 mm) depth must are permitted in this area.
be smoothed and radiused out over
0.120 inch (3.048 mm) area on each side AREA C: No repairs permitted.
of damage. Defects beyond 0.030 inch
(0.762 mm) depth are cause for rejec- AREA D: Dents and depressions
tion. exceeding 0.005 inch (0.127 mm)
without sharp change in section to a
AREA 7: Scratches, nicks, or gouges up maximum of 0.030 inch (0.762 mm)
to 0.005 inch (0.127 mm) deep and must be repaired.
detectable with 5X magnification are
not acceptable without repair. Defects AREA E: Dents and depressions
beyond 0.005 inch (0.127 mm) depth are exceeding 0.010 inch (0.254 mm)
cause for rejection. Gouges, nicks, without sharp change in section to a
scratches and cracks not exceeding maximum of 0.040 inch (1.016 mm)
0.250 inch (6.35 mm) depth on trailing must be repaired.
edge, except for AREA 8, must be
smoothed and radiused out to 0.250 AREA F: Dents and depressions
inch (6.35 mm) area on each side of exceeding 0.010 inch (0.254 mm)
damage center. Defects beyond 0.250 without sharp change in section to
inch (6.35 mm) depth require blade maximum of 0.040 inch (1.016 mm)
replacement. must be repaired.
AREA 8: Check for gouges, nicks, AREA G: No repairs permitted.

scratches and cracks detected by using
a bright light and 5X magnification at AREA H: Dents and depressions
trailing edge corners where blade and exceeding 0.010 inch (0.254 mm)
tabs join. View area from different without sharp change in section to
angles during inspection. Damage at maximum of 0.040 inch (1.016 mm)
this point not exceeding 0.030 inch must be repaired.
(0.762 mm) depth must be smoothed
and radiused out over a 0.120 inch AREA J: Dents and depressions
(3.048 mm) area on each side of exceeding 0.010 inch (0.254 mm)
damage. Defects beyond 0.030 inch without sharp change in section to
(0.762 mm) depth (Ref. Trim Tab maximum of 0.040 inch (1.016 mm)
Damage Repair). must be repaired. Dents and depres-
sions exceeding these limitations, refer
(3). (Ref. Figure 602) Depth limitations for to trim tab damage repair.
surface dents or depressions in eight
areas of blade skin are described below. (4). Inspect surface areas of upper and
A dent or depression is defined as a lower root fittings (other than AREA 5)
smooth depression or discontinuity with for evidence of nicks, scratches, and
no sharp changes in section. wear spots. Nicks, scratches, and wear
spots deeper than 0.010 inch (0.254
mm) in attachment lug area, and bolt
AREA A: Dents and depressions hole area are not repairable. Damage
exceeding 0.015 inch (0.381 mm) 0.010 inch (0.254 mm) deep or less
without sharp changes in section to a must be repaired.
maximum of 0.062 inch (1.575 mm)
must be repaired.
(5). Inspect four attachment lug bushings
in root fittings (Ref. Figure 401) for
AREA B: Dents and depressions to a security, and evidence of cracks or
maximum of 0.010 inch (0.254 mm) are severe scoring.
Page 602
Revision 20 621000
MAINTENANCE MANUAL
DAMAGE 0.010 INCH (0.254 MM)

IN DEPTH OR LESS IS REPAIR-
ABLE IN THESE AREAS (NOTE
1) CHORD LINE
1.00 INCH (2.54 CM) RADIUS AROUND LAST 1
2 BOLT HOLES 0.001 INCH (0.025 MM) MAXI- SPAN LINE
5 MUM DEPTH 0.380 INCH
(9.652 MM)
90
3.00 INCH 120
4 (7.62 CM) 2
1.25 30 30
120
120 1.00 INCH
3
(2.54 CM)
305 30 120 30 30
DAMAGE LESS THAN 15
0.030 INCH (0.762 MM) 6
DEPTH REPAIRABLE IN
THIS AREA (NOTE 1)
30 15
8 7 8
23.00 INCH
(58.42 CM)
GOUGES, NICKS AND CRACKS
SCRATCHES GOUGES AND NICKS TRAILING EDGE ONLY
ORIENTATION MAXIMUM DEPTH WITH- MAXIMUM DEPTH MAXIMUM DEPTH WITH- MAXIMUM DEPTH MAXIMUM DEPTH WITH- MAXIMUM DEPTH WITH
AREA OUT REPAIR WITH REPAIR REPAIR
FROM SPANLINE OUT REPAIR WITH REPAIR OUT REPAIR
1 090 MINOR WITHOUT MINOR WITHOUT MINOR WITHOUT MINOR WITHOUT

SKIN PENETRATION SKIN PENETRATION SKIN PENETRATION SKIN PENETRATION
2 030 0.005 INCH (0.127 MM) 0.005 INCH (0.127 MM) 0.003 INCH (0.076 MM) 0.005 INCH (0.127 MM)
3090 0.003 INCH (0.076 MM) 0.003 INCH (0.076 MM) 0.003 INCH (0.076 MM) 0.005 INCH (0.127 MM)

3 030 NONE 0.005 INCH (0.127 MM) NONE 0.005 INCH (0.127 MM) N/A N/A
3090 NONE 0.003 INCH (0.076 MM) NONE 0.005 INCH (0.127 MM)
4 030 NONE 0.003 INCH (0.076 MM) NONE 0.003 INCH (0.076 MM)
5 090 NONE 0.001 INCH (0.025 MM) NONE 0.001 INCH (0.025 MM)
(NOTE 2) (NOTE 2)
(NOTE 2)
015 0.005 INCH (0.127 MM) 0.005 INCH (0.127 MM) NONE 0.005 INCH (0.127 MM)
0.030 INCH (0.762 MM)
6 1530 0.003 INCH (0.076 MM) 0.005 INCH (0.127 MM) NONE 0.005 INCH (0.127 MM) NONE
(NOTES 2, 4)
7 0.005 INCH (0.127 MM) 0.005 INCH (0.127 MM) 0.250 INCH (6.35 MM)
090 NONE NONE NONE
(NOTE 2) (NOTES 2, 5) (NOTES 2, 3, 5)
8 NOT APPLICABLE NONE 0.030 INCH (0.762 MM)

(NOTES 2, 4, 5)
TAB END
NOTES:
1. DAMAGE LIMITS APPLY TO BOTH UPPER AND LOWER ROOT FITTING 4. SMOOTHED AND RADIUSED CLEANOUT OVER 0.120 INCH (3.048 MM)
SURFACES. AREA ON EACH SIDE OF DAMAGE.
2. INSPECTION UNDER 5X MAGNIFICATION (MINIMUM) REQUIRED. 5. REFER TO TRIM TAB DAMAGE REPAIR.
3. AREAS NOTED: 0.250 INCH (6.35 MM) SMOTHERED AND RADIUSED
CLEANOUT ALLOWED.
G621001A
Figure 601. Main Rotor Blade Damage and Repair Limits

Nicks, Scratches, Gouges and Cracks
Page 603
621000 Revision 20
MAINTENANCE MANUAL
(6). Inspect damperattachment bearing for and aft balance weights (Ref.
binding, evidence of galling or scoring Figure 401) for security. Weights are
in bore and wear. No radial play is normally recessed 0.050 inch (1.270
permissible. Maximum axial play is mm) inside end surface of tip. Security
0.015 inch (0.381 mm). of weights may be checked by using
torque wrench with screwdriver socket
(7). Inspect all bonded areas for evidence of in slot of weight to detect if weight can
separation. If there appears to be be rotated by less than 20 inch
separation of trailing edge bond, lightly pounds (2.26 Nm). If torque wrench is
probe joint with a 0.0010.002 inch not available, check weight security by
(0.0250.051 mm) plastic inspection fitting small coin in weight slots and
tool. If plastic inspection tool can be applying maximum force that can be
inserted to a depth of 1/2 inch (12.70 exerted by only index finger and thumb.
mm) or more, either above or below V If weights are found to be loose,
insert, separation is excessive. retighten (Ref. Loose Balance Weight
Repair).
NOTE: Trailing edge structural bond line to V
insert starts 1/4 inch (6.35 mm) in (chord- 2. Main Rotor Blade and Damper Attach Pin
wise) from trailing edge joint: therefore Inspection and Corrosion Protection
above tolerance allows 1/4 inch (6.35 mm)
separation. Be sure measurement is taken (Ref. Figure 603)
from trailing edge joint, not tab trailing
edge. Maximum trailing edge joint gap al- Consumable Materials
lowed during fabrication is 0.080 inch (2.032 (Ref. Section 910000)
mm). Item Nomenclature
(8). Inspect doubler shown in AREA G CM120 Oil, corrosion preventive
(Ref. Figure 602) for bonding voids
between doubler and blade skin top and (1). Inspect pin cam handle lobe for cracks
bottom. Use a heavy coin and lightly and excessive wear. Remove pin from
tap doubler surface. A void is detected service if cracking or excessive wear is
by a distinct change in sound. Note that noted.
tapping sounds differ slightly due to
blade structure in leading and trailing NOTE: If hard anodizing surface of cam lobes is
edge, internal channel and doubler worn, cam lobes can be reanodized or
areas. Allowable voids or debonds on treated with corrosion preventive oil
main rotor blade ribs are as follows: (CM120).
(a). 50% void or debond. (2). Inspect attach pin for evidence of
corrosion, or wear, and for straightness.
(b). Maximum four (4) ribs, no more than Pay particular attention to area along
two (2) adjacent for the 369D21100 edges of barrel nut and bore in cam
and 369D21102 blades. handle. Remove pin from service if
corrosion or wear is noted or if pin is
(9). Ensure that vent holes are open (Ref. bent.
Figure 401).
NOTE: If subject to salt laden atmosphere, fol-
(10). Inspect fasteners that secure upper and lowing corrosion prevention treatment is to
lower root fittings, and six rivets that be applied at each periodic inspection to en-
secure skin to spar near tip, for securi- sure continued serviceability of attach pin;
ty. Inspect forward tip cap screw insert and at each pin removal.
for security and thread damage. Inspect
trailing edge upper and lower weights (3). With attach pin removed, lubricate
for debonding and loose rivets. mating surfaces of barrel nut and cam
handle, using corrosion preventive oil
(11). When continuous oneperrevolution (CM120). Rotate cam handle back and
lateral vibration occurs, inspect forward forth on barrel nut several times to
Page 604
Revision 20 621000
MAINTENANCE MANUAL
ensure that oil penetrates all sections of (1). Inspect tip caps for evidence of corro-
pin operating mechanism. Wipe excess sion, with particular attention at
oil from pin surfaces. mating area of blade skin to tip weight
interface. Verify integrity of sealant
3. Main Rotor Blade and Damper Attach Pin coating.
Disassembly and Special Inspection
(Ref. Figure 603) This inspection is to be (2). If damage is evident, remove tip caps
preformed in event of a main rotor blade and apply penetrating oil to blade tip
strike. weight area. Oil arrests any corrosion
between blade skin and weight assem-
bly.
(Ref. Section 910000) (3). Using brush and clean cloth, clean area
Item Nomenclature with isopropyl alcohol (CM217). Dry
CM217 Isopropyl alcohol with clean cloth.
Do not intermix bushings, (4). Spray area with light film of rust
CAUTION spacers and thrust washers be- inhibitor (CM232); then apply thin film
tween bolts. Component parts make up a of primer and paint lightly as required
single bolt assembly. (Ref. Sec. 204000).
(1). Remove adjusting nut and remove 5. Main Rotor Blade Upper and Lower Root
adjusting bushings, spacers and thrust Fitting Attach Lug and LeadLag Link
washers from pin. Attach Lug Inspection (25 Hour)
(2). Using brush and clean cloth, clean
parts with isopropyl alcohol (CM217). (Ref. Figure 604 and Figure 605) The following
Dry with clean cloth. procedure pertains to helicopters equipped
with 369D21100BSC thru 515 and
(3). Inspect pin as follows: 369D21102BSC and 501 main rotor blades
and/or 369H1203BSC, 11, 21 and 31
(a). Fluorescent inspect pin per MIL leadlag link assemblies.
STD6866.
(b). Magnetic particle inspect thrust
washers, bushings and spacer per
MILSTD1949.
Item Nomenclature
(4). Reassemble pin in sequence as follows; CM805 Dye penetrant kit
install thrust washer, three (3) adjust-
able bushings, spacer, three (3) adjust-
able bushings and secure with adjust- NOTE: Main rotor blades and hub assemblies
ing nut. installed on helicopters operating in a salt
water or corrosive environment should be
4. Main Rotor Blade Forward Tip Cap
cleaned and washed on a daily basis as a
Inspection and Corrosion Protection
preventative measure to arrest corrosion
(Ref. Figure 603) (Ref. Main Rotor Hub Corrosion Prevention
(TriFlow Wash Procedures)).
(1). Visually inspect exposed portion of all
installed main rotor blade upper and
Item Nomenclature
lower root fitting attach lugs, and main
CM217 Isopropyl alcohol rotor hub leadlag link attach lugs, for
CM232 Rust inhibitor spray broken or cracked lugs, corrosion or
other damage to the lug areas.
Page 605
621000 Revision 20
MAINTENANCE MANUAL
2.12 INCH 0.38 INCH

(5.385 CM) (9.652 MM)

1.58 INCH

(3.81CM)
2.00 INCH
(5.08 CM) 0.58 INCH
(14.732 MM) 2.17 INCH
0.96 INCH 23.00 INCH
(5.512 CM)
(24.384 MM) (58.42 CM)
DENTS AND DEPRESSIONS
MAXIMUM MINIMUM DISTANCE

MAXIMUM DEPTH MAXIMUM DEPTH MAXIMUM NUMBER BETWEEN DEFECT
AREA WITHOUT REPAIR ALLOWED
WITH REPAIR OF DEFECTS CENTERS
AREA
1.5 INCH (3.81 MM)

0.015 INCH 0.062 INCH
X 1 N/A
(0.381 MM) (1.575 MM)
1.5 INCH (3.81 MM)
0.250 INCH (6.35 MM)

0.010 INCH

0.000 X 2 18
(0.254 MM)
0.25 INCH (6.35 MM)
0.000 0.000 0.000

NONE
ALLOWED N/A

1.5 INCH (3.81 MM)
0.005 INCH 0.030 INCH X 2 18
(0.127 MM) (0.762 MM) 1.5 INCH (3.81 MM)
0.010 INCH 0.040 INCH 1.5 INCH (3.81 MM)

(0.254 MM) X 2 18
(1.016 MM)
1.5 INCH (3.81 MM)
0.010 INCH 1.5 INCH (3.81 MM)

0.040 INCH 3 18
(0.254 MM) X
(1.016 MM)
1.5 INCH (3.81 MM)
0.000 0.000 0.000 NONE N/A

ALLOWED
0.010 INCH 1.5 INCH (3.81 MM)

0.040 INCH X
(0.254 MM) 1 N/A
(1.016 MM) 1.5 INCH (3.81 MM)
0.350 INCH 1.5 INCH (3.81 MM)

0.010 INCH (8.89 MM) X N/A N/A
(0.254 MM) (NOTE 2) 1.5 INCH (3.81 MM)
NOTES:
1. N/A NOT APPLICABLE.
2. REFER TO TRIM TAB DAMAGE REPAIR. G621002B
Figure 602. Main Rotor Blade Damage Limits for Dents and Depressions
Page 606
Revision 40 621000
MAINTENANCE MANUAL
OIL
BARREL NUT
OIL
CAM HANDLE
THRUST WASHER
BUSHING SEGMENTS
SPACER
SAFETY LATCH
G621008
Figure 603. Main Rotor Blade Attach Pin
Page 607
621000 Revision 20
MAINTENANCE MANUAL
NOTE: If movement is suspected but cannot be

verified with the blades installed, remove Consumable Materials
those blades and inspect bushings for move- (Ref. Section 910000)
ment. Item Nomenclature
(2). Using a bright light, inspect slippage CM318 Primer
marks on the root fitting bushings to CM420 Sealant
ensure there has been no movement of
CM805 Dye penetrant kit
the bushings. If bushings have moved,
replace main rotor blade before next
flight. Return those main rotor blades (1). Remove affected main rotor blades (Ref.
where bushing movement has occurred Main Rotor Blade Removal).
to MDHI for possible rework.
CAUTION
CAUTION D If cracked or broken lug is noted in main
rotor blade upper and lower root fittings,
D If broken or cracked lugs are noted in replace main rotor blade (Ref. Main Rotor
main rotor blade upper and lower root fit- Blade Removal) before further flight.
tings, replace main rotor blade before fur-
ther flight (Ref. Main Rotor Blade Remov- D If cracked or broken lug is noted in main
al). rotor leadlag links, replace or repair
main rotor hub before further flight (Ref.
D If broken or cracked lugs are noted in Sec. 6220) (Ref. NOTE: below).
main rotor leadlag links, replace main D If a crack is suspected in either the rotor
rotor hub (Ref. Sec. 6220) (Ref. NOTE: blade or leadlag link attach lug, perform
below). dye penetrant (CM805) inspection per
D If cracking is suspected in either the rotor MILI25135 of lug. If a crack in noted,
blade or hub leadlag link attach lugs, replace main rotor blade (Ref. Main Rotor
perform dye penetrant (CM805) inspec- Blade Removal) or replace or repair main
tion of lugs per MILI25135. If cracking rotor hub assembly (Ref. Sec. 6220) (Ref.
is noted, replace main rotor blade (Ref. NOTE: below).
Main Rotor Blade Removal) or replace or NOTE: Do not remove bushings or corrosion in-
repair main rotor hub assembly (Ref. Sec. hibiting sealer.
6220), before further flight (Ref. NOTE:
below). (2). Using bright light and 5X magnifying
glass, visually inspect the attach lugs of
NOTE: LeadLag link assemblies may only be all main rotor blade upper and lower
replaced by MDHI authorized personnel or root fitting and main rotor leadlag
under MDHI supervision. Contact your local links for broken or cracked lugs,
MDHI Field Service Representative for fur- corrosion or other damage to the lug
ther information. areas.
NOTE:
6. Main Rotor Blade Upper and Lower Root D Pay particular attention to area around
Fitting, Attach Lug and LeadLag Link attach pin hole bushings in the lugs.
Attach Lug Inspection (100 Hour)
D Pay particular attention to the cross
hatched areas.
(Ref. Figure 604 and Figure 605) The following
procedure pertains to helicopters equipped (3). If slippage marks have already been
with 369D21100BSC thru 523, applied, inspect the root fitting for any
369D21120501, 369D21102BSC thru 523 indication of movement of the bushings;
and 369D21121501 main rotor blades and/or no movement is allowed. Return main
369H1203BSC, 11, 21 and 31 leadlag rotor blades that have root fitting
link assemblies. bushing movement to MDHI for
Page 608
Revision 33 621000
MAINTENANCE MANUAL
possible rework. If slippage mark is (5). Inspect leadlag link blade attach pin
degraded, reapply. hole bushings for any indication of
movement of the bushings in the links.
(4). Perform main rotor blade upper and If any of the bushings have movement,
lower root fitting inspection as follows: replace the links.
(a). Inspect main rotor blade root fitting
If required, apply a light but
for missing (no squeezeout) or CAUTION thorough coat of sealer (CM420)
cracked adhesive/paint around the
or primer (CM318) around bushings. Note
periphery of the root fitting. If this
that excessive amounts of sealant or primer
condition exists, proceed as follows:
around the bushings are not desirable and
1). Loosen, but do not remove the can unbalance the main rotor system.
extreme outboard bolt.
(6). If sealing compound is not already
2). Insert a 0.004 inch (0.102 mm) installed or becomes loose, clean and
thick piece of mylar/viewfoil then seal all junctions between all the
between the fitting and the dou- steel bushings and the main rotor blade
bler. root fitting attach lugs with a film of
sealing compound or zincchromate
3). If the mylar can be inserted, primer without removing the bushings.
contact Field Service Representa-
tive for disposition of blade. (7). For the main rotor blade root fitting
attach lugs, carefully remove sufficient
4). If the insertion is 0.10 inch (2.54 amount of sealant and paint from only
mm) or greater, remove blade from the bushing in the area where the
service. slippage mark is to be applied (if not
NOTE: Measurement of the insertion is from already done). Using isopropyl alcohol
the edge of the root fitting. (CM217), clean the area where the
slippage mark is going to be applied to
5). Retorque root fitting outboard bolt allow adequate adherence of epoxy
to 60 65 inchpounds (6.78 paint.
NOTE:
In the following step, a crack
CAUTION might be difficult to detect if D Locate slippage mark in a position that
bright light is not used. can be viewed at subsequent inspections
with main rotor blade installed in the
NOTE: The lower side of the blade is more sus- hub. Slippage marks should not be ap-
ceptible to cracking. plied to crosshatched areas to preclude
masking possible cracks.
(b). Using a bright light, inspect doubler
and root fitting, paying particular D Insure that slippage mark is applied to
attention to the lower side, for bushing at upper and lower root fitting in-
cracks. If crack is found, blade is to side surfaces.
be scrapped. D Do not use torque seal.
NOTE: LeadLag link assemblies may only be (8). Apply epoxy paint slippage marks to
replaced by MDHI authorized personnel or four locations as shown.
under MDHI supervision. Contact your local
Field Service Representative for further in- (9). Install main rotor blades (Ref. Main
formation. Rotor Blade Installation).
Page 609
621000 Revision 29
MAINTENANCE MANUAL
7. Main Rotor Blade Leading Edge Abrasion 8. Main Rotor Blade Torque Event Inspection
Strip Check
(Ref. Figure 604)
The leading edge abrasion strip should be
checked prior to each flight or on every daily NOTE: This inspection requires the use of a
check. The following is a comprehensive bright light.
checklist: (1). Lifting from the outboard end of the
blade, lift blade off the droop stop.
NOTE: If void is noted towards end of blade, re-
move tip cap and check for presence of bal- (2). Inspect the bottomside of the blade as
ance weights. If weights are not installed, a follows:
false indication of a void is possible.
(a). Using a bright light and 10x magni-
(1). Check for any blistering, bubbling or fying glass, inspect for chordwise
lifting of the abrasion strip; this cracks protruding from under root
indicates a void. fitting and doubler (View C and Note
7).
(a). Voids cannot be closer than 0.50 inch
(12.70 mm) to any outside edge of (b). Inspect the area around the root
abrasion strip. fitting, doubler and skin for cracks.
(b). Voids exceeding 1.5 square inch (c). Inspect the attach lugs at the bush-
(9.677 square cm) are unacceptable. ings for cracks.
(c). Voids cannot be closer than one inch (d). Inspect the entire length of the blade
(2.54 cm) to any other void. for cracks.
(2). Number of acceptable voids depends (e). Lower blade back onto droop stop.
upon length of abrasion strip.
(3). With blade resting on the droop stop,
(a). There cannot be more than three inspect the topside of the blade as
voids on either the top or bottom of follows:
the 36 inch (91.44 cm) long abrasion
(a). Inspect the area around the root
strip surface.
fitting, doubler and skin for cracks.
(b). There cannot be more than two voids (b). Inspect the attach lugs at the bush-
on either the top or bottom of the 18 ings for cracks.
inch (45.72 cm) long abrasion strip
surface. (c). Inspect the entire length of the blade
for cracks.
(3). Record all voids in regards to size and
location in the helicopter log book and (4). If any of the above defects are found,
check each void prior to each flight for the main rotor blade is to be rejected
growth and acceptable criteria. and scrapped.
Page 610
Revision 35 621000
MAINTENANCE MANUAL
NOTES 2, 3 AND 4
DOUBLER
NOTE 6
ROOT FITTING
NOTE 5
(NOTES 1, 2 AND 3) NOTE 7
NOTE 5
VIEW LOOKING UP
ROTATED
LOOSEN BUT DO NOT REMOVE BOLT.
RETORQUE BOLT TO 60 65 INCHPOUNDS
(6.78 7.34 NM) PLUS DRAG TORQUE.
UPPER ROOT FITTING ATTACH LUG
(TYP 2 PLACES) (NOTE 1)
NOTE 5
LEADLAG LINK ATTACH LUG
(TYP 8 PLCS) (NOTE 1)
MAIN ROTOR BLADE
LOWER ROOT FITTING AT-

TACH LUG (TYP 2 PLCS)
(NOTE 1)
NOTES:
1. VISUALLY INSPECT AREAS OF ALL ROOT FITTINGS AND LEADLAG ATTACH LUGS FOR CRACKS OR
BREAKS. INSPECT BLADE ATTACH BUSHINGS FOR LOOSENESS. IF LOOSE, REPLACE LEADLAG LINKS.
2. PAY PARTICULAR ATTENTION TO AREA AROUND ATTACH PIN HOLES IN LUGS.
3. SEAL ALL JUNCTIONS BETWEEN BUSHINGS AND ATTACH LUGS WITH SEALER OR PRIMER (CM318).
4. LEADLAG LINK ASSEMBLIES ARE SUBASSEMBLIES OF THE MAIN ROTOR HUB ASSEMBLY.
5. INSPECT MAIN ROTOR BLADE UPPER AND LOWER ROOT FITTING FOR MISSING OR CRACKED ADHESIVE.
6. USING BRIGHT LIGHT, INSPECT MAIN ROTOR BLADE DOUBLER FOR CRACKS. PAY PARTICULAR ATTENTION
TO BOTTOM SIDE OF BLADE, JUST BEYOND ROOT FITTING AND IN LINE WITH ROOT FITTING ATTACH BOLTS.
7. USING A BRIGHT LIGHT AND 10X MAGNIFYING GLASS, INSPECT FOR CHORDWISE CRACKS PROTRUDING
FROM UNDER ROOT FITTING AND DOUBLER.
G621009D
Figure 604. Main Rotor Blade Root Fitting, Attach Lugs and LeadLag Link
Assembly Inspection
Page 611
621000 Revision 35
MAINTENANCE MANUAL

* ONLY REMOVE 1/2 DEPTH OF

CORROSION INHIBITING SEALER
AT LOCATION WHERE SLIPPAGE

MARK IS TO BE APPLIED.
UPPER ROOT FITTING
SLIPPAGE MARK LOCATIONS


(INSIDE SURFACES)

DO NOT APPLY SLIPPAGE MARK
TO CROSSHATCH AREAS LOWER ROOT FITTING

VIEW LOOKING UP

(LAG SIDE SHOWN)
(LEAD SIDE OPPOSITE)
UPPER AND LOWER
88675
Figure 605. Application of Slippage Mark to Main Rotor Blade Bushings and Root Fittings
Page 612
Revision 20 621000
MAINTENANCE MANUAL
MAIN ROTOR BLADE

REPAIRS
1. Main Rotor Blade Repair (Nicks,
Scratches and Wear Spots) CAUTION
D Repair only those damaged areas that are
Consumable Materials within repairable limits specified.
Item Nomenclature D Do not use chemical paint remover to re-
move paint from abrasion strip. Chemi-
cals can attack the abrasion strip to blade
CM801 Abrasive paper, silicon carbide bonding agent.
(Ref. Figure 601) (1). Using abrasive paper (CM801), not

coarser than grade 320, remove paint
Do not use chemical paint re- from surface area to be repaired.
CAUTION mover to remove paint from
abrasion strip. Chemicals can attack the (2). Clean abraded area with clean cloth
abrasion strip to blade bonding agent. dampened by solvent (CM234). Allow to
(1). Using abrasive paper (CM801), not dry for minimum of 15 minutes.
coarser than grade 320, remove nicks,
scratches and wear spots from upper (3). Mask edges of repair areas with one
and lower root fittings, and from blade layer of tape (CM708).
skin.
Do not cut tape after it is
(2). Use finer grade of paper, as necessary CAUTION applied to blade.
to restore surface roughness to original
finish. (4). Mix filler (CM507), three parts "A" and
two parts "B" by weight. Mix thorough-
(3). Remove material in such a manner that ly until mixture is dark red in color. An
no abrupt changes occur in surface alternate filler (CM508) may be used if
contours. equal parts "A" and "B" by weight are
(4). Apply chemical film surface treatment mixed.
(CM206) to repaired surface(s) (Ref.
Sec. 2030). (5). Allow filler to cure for minimum of 24
hours at room temperature.
2. Main Rotor Blade Repair (Dents,
Depressions and Erosion) (6). Smooth filler area with grade 400
(Ref. Figure 602) abrasive paper (CM801). Limit smooth-
ing to masked area.
Consumable Materials (7). Remove the tape and inspect alclad
(Ref. Section 910000) coating of area around repair. Penetra-
Item Nomenclature tion of coating is cause for blade
CM220 Naphtha aliphatic replacement.
CM229 Paint remover
CM234 Solvent, drycleaning (8). Clean repaired area with a cloth
CM304 Enamel, epoxy dampened by solvent (CM220).
CM507 Resin, filler
(9). Apply chemical film treatment to
CM508 Resin, filler repaired surface (Ref. Sec. 203000).
CM708 Tape
CM801 Abrasive paper, silicon carbide (10). Touchup reworked area with paint
(CM304) as required.
Page 801
621000 Revision 33
MAINTENANCE MANUAL
3. Trim Tab Damage Repair (6). If excessive damage requires full or

partial removal of trim tab from blade,
(Ref. Figure 802) perform the following (no minimum
length of trim tab is required):
Consumable Materials (a). Position blade on workbench so that
(Ref. Section 910000) a straight edge is provided for cutting
Item Nomenclature or filing off trim tab.
CM220 Naphtha aliphatic Cutting, grinding or filing to re-
CAUTION move trim tab, and deburring of
reworked blade trailing edge, are to be per-
CM304 Enamel, epoxy formed in a SPANWISE direction only. Do
CM318 Primer NOT use shears or clippers to remove trim
tab.
Provide protective surface and/ (b). Use metal cutting saw or equivalent
CAUTION or covering to prevent scratch- to remove the 0.38 inch (9.65 mm)
ing, nicking or other damage to blade during wide trim tab per dimensions shown
rework. Position blade on work bench or Ref. Figure 802, View AA). Deburr
equivalent. edges in a SPANWISE direction only.
NOTE: No minimum length of trim tab is re- (7). Peel and remove tape from blade and
quired. In addition, the entire trim tab, or inspect area around repair; clean
portion of the trim tab, may be removed if repaired area with cloth dampened in
required. Removal of entire trim tab elimi- naptha (CM220).
nates adjustment of blade tracking capabili-
ty for that blade. Main rotor blades with and (8). Apply chemical film treatment (CM206)
without trim tabs are 100% interchange- to reworked area of blade trailing edge
able, individually and in ship sets. or trim tab; apply a thin film of primer
(CM318) and paint (CM304) lightly.
(1). Remove main rotor blade with damaged
trim tab. (9). Reinstall main rotor blade and perform
track and balance (Ref. Sec. 1810).
(2). Wipe away dirt on and around trim tab
area with clean cloth dampened with
NOTE: Removal of entire trim tab eliminates
dry cleaning solvent (CM234).
adjustment of blade tracking capability for
that blade.
(3). Mask edges of blade area around trim
tab area with tape; do NOT cut tape
after it has been applied to blade. 4. Forward Tip Cap Threaded Insert Repair
(4). Remove damaged area of trim tab by

making Vtype cut with 45 sides
joined by a 0.25 inch (6.35 mm) radius
Item Nomenclature
at the bottom of the V. Maximum Vcut
depth is 0.35 inch (8.89 mm); do not cut CM318 Primer
past trim tab area into main portion of
blade.
Replace a loose or stripped insert. Use
(5). If damage occurs within 1 inch (2.54 selflocking insert of correct size and install
cm) of either or both ends of trim tab, with wet primer (CM318). Comply with
remove tab end(s) and restore contour replacement requirements of applicable NAS
as shown. standard.
Page 802
Revision 20 621000
MAINTENANCE MANUAL
MS2070AD3
RIVETS (2 PLS) 6.312 INCH
(16.033 CM)
(REF)
EXISTING EXISTING
BLADE RIVET EXISTING BLADE RIVET
BLADE RIVET
A
1.58 INCH
A (4.013 CM)
(REF)
0.75 INCH
(19.05 MM)
9.25 INCH
(23.495 CM)
369D21106 UPPER EXTERNAL

TRAILING EDGE WEIGHT
(369D21100 ONLY)
369D21106 LOWER EXTERNAL

TRAILING EDGE WEIGHT
(369D21100 ONLY)
VIEW A A
(ROTATED 90)
NOTES: POSITION WEIGHT ONTO BLADE (ONE EACH ON UPPER

AND LOWER SURFACES) BY ALIGNING CENTERS OF HOLES IN
WEIGHT TO EXISTING RIVETS ON BLADE.
G621003A
Figure 801. Main Rotor Blade Trailing Edge Weight Rework.
Page 803
621000 Revision 20
MAINTENANCE MANUAL
5. Loose Balance Weight Repair (4). Mix epoxy adhesive (CM409) per
manufacturers instructions and apply
(Ref. Figure 401) Reinstall loose forward and aft to bonding surfaces.
balance weights as follows:
(5). Position weights on blade by aligning
holes in weights to existing rivet holes
Consumable Materials on blade and apply light pressure to
(Ref. Section 910000) weights until epoxy sets.
Item Nomenclature
CM431 Sealing, locking and retaining compound (6). Install (3 ea.) rivets in existing holes.
(7). If not already installed, install two
more rivets as follows.
(1). Unscrew loose weight until it projects
approximately onehalf inch (12.7 mm) (a). Mark location of rivets to be in-
and remove old accumulation of stalled.
powdered compound. (b). Drill holes at marked locations.
(2). Apply grade A locking compound (c). Deburr and clean debris from holes.
(CM431) and screw weight back into
blade until slotted end of weight is (d). Coat all exposed surfaces with primer
recessed 0.050 inch (1.27 mm) below tip (CM318).
surface. Wipe off excess compound. (e). Install rivets.
Allow to cure for a minimum of (f). Allow epoxy adhesive to cure per
CAUTION 12 hours. If faster cure is de- manufacturers instructions before
sired, complete cure can be obtained by al- flying aircraft.
lowing part to set for 30 minutes at room
temperature and then heating for 30 min- 7. Loose or Missing Rivets or Aft Tip Cap
utes at approximately 212F (101C). Repair
(Ref. Figure 401) Replace all loose or missing
(3). If locking compound is not available, rivets. Reinstall or replace loose or missing aft tip
screw weight into normal position and cap as follows:
centerpunch end of weight into mating
threads at three evenly spaced points to
prevent rotation. Consumable Materials
6. Loose Trailing Edge Weight Repair Item Nomenclature
(Ref. Figure 801)
CM318 Primer
Consumable Materials CM801 Abrasive paper, silicon carbide
Item Nomenclature
NOTE: Spare tip caps are supplied with bond-
ing surface coated with nylon primer to fa-
CM318 Primer cilitate installation. Main rotor balance is
CM409 Adhesive, epoxy not affected by following repair.
(1). Lightly abrade primed surfaces of tip
cap with grade 180 abrasive paper
(1). Carefully remove loose or partially (CM801). Wipe away residue with cloth
debonded weights. dampened in solvent (CM234) and
allow tip cap to dry at room tempera-
(2). Abrade debonded surface using ture for 30 minutes.
#200300 grit emery cloth (CM804).
(2). Mix twopart bonding adhesive
(3). Clean bonding surfaces with naptha (CM411) in equal proportions by
aliphatic (CM220). weight.
Page 804
Revision 20 621000
MAINTENANCE MANUAL
NOTE 2 NOTE 2
NOTES 2, 3
TOP
6.80 INCH (17.272 CM)
SURFACE
0.38 INCH
(9.652 MM) NOTE 1 NOTE 3
0.00 0.10 INCH
(0.00 2.54 MM)
0.38 INCH NOTE 4
(9.652 MM) 1.00 INCH
1.00 INCH (2.54 CM)
VIEW AA (2.54 CM)
NOTES:
1. REMOVE DAMAGED END(S) IF THEY OCCUR WITHIN 1 INCH (2.54 CM) OF TAB ENDS.
2. 0.25 INCH (6.35 MM) RADIUS CLEANUP. FINISH PER BASIC HMI.
3. MAXIMUM DEPTH OF REPAIR 0.35 INCH (8.89 MM).
4. NO MINIMUM LENGTH OF TAB REQUIRED. IF DAMAGE OCCURS AT BOTH ENDS, IT IS
PERMISSIBLE TO REMOVE AT BOTH ENDS.
5. ENTIRE TAB MAY BE REMOVED IF REQUIRED.
G
Figure 802. Repair and Removal of Trim Tab, Main Rotor Blade
0.002 INCH
(0.0508 MM)
MAXIMUM
EDGE OF
STAKING TOOL
FLUSH TO
+0.010 INCH
ARM (+0.254 MM)
BEARING WITH STAKING
GROOVE IN OUTER RACE
PRESSING STAKING
BEARING IN ARM BEARING IN ARM
G62 1005A
Figure 803. Bearing Replacement Main Rotor Blade Damper Attach Fitting
Page 805
621000 Revision 20
MAINTENANCE MANUAL
(3). Apply bonding adhesive to abraded tip (5). Measure fitting bore diameter. Accept-
cap and mating surfaces at rotor blade able limits are 0.74880.7493 inch
tip. To extent possible, be sure that (19.0195219.03222 mm).
there are no adhesive voids.
(6). Apply thin coat of primer (CM318) to
(4). Install tip cap in blade tip, apply fitting bore.
uniform clamping pressure to joint, and
wipe away excessive adhesive. Allow to (7). Press bearing into fitting with arbor
cure for eight hours at room tempera- press and fixture (ST709). Wipe away
ture or two hours at 150F (66C). excess primer.
(5). Install two MS20604AD3C2 blind (8). Stake bearing at both sides of fitting
rivets, one though each side of blade tip with staking tool (ST710) in hydraulic
and tip cap. press with 60008000 pounds
(27223629 Kg) of force. When staked,
outer race of bearing shall be flush to
8. Damper Attach Blade Fitting Bearing
not more than 0.010 inch (0.254 mm)
Replacement
above fitting surface (both sides). Gap
between staked lip of bearing race and
(Ref. Figure 803)
chamfered surface of fitting bore shall
not exceed 0.002 inch (0.0508 mm) as
Consumable Materials checked with feeler gage. Staking
(Ref. Section 910000) operation shall produce no cracks in
Item Nomenclature fitting or bearing.
CM216 Loctite remover (9). Fill staking gap, if any, with primer
CM219 Methylethylketone (CM318).
CM318 Primer
9. Leading Edge Protective Tape
Special Tools Replacement
Item Nomenclature (Ref. Figure 804 and Figure 805) Replace
protective tape when it is abraded. Operation in
ST709 Arbor press fixture rain reduces tape life and more frequent replace-
ST710 Staking tool ment is necessary.
(1). Use fly or circle cutter with 5/16 inch Consumable Materials
(7.9375 mm) pilot to remove staked lip (Ref. Section 910000)
from one side of bearing without Item Nomenclature
removing any material from fitting. If CM220 Naphtha aliphatic
fitting is damaged by cutter, blade must CM801 Abrasive paper, silicon carbide
be replaced.
(2). Use an arbor press to press bearing (1). Lightly abrade faying surface of main
from fitting. rotor blade with 400 grit abrasive paper
(CM801).
(3). Clean primer residue from fitting bore
with MEK (CM219). Remove locking (2). Wipe faying surface of blade with
compound residue, if any, with locking naptha aliphatic (CM220) to eliminate
compound remover (CM216). grease or dirt film.
(4). Using 10power magnifying glass, (3). Use heat gun or equivalent to warm
inspect fitting bore for cracks. No blade faying surface. Temperature must
cracks are permitted. not exceed 120F (49C).
Page 806
Revision 20 621000
MAINTENANCE MANUAL
24.00 INCH
(60.96 CM)
NOTE 1
MAIN ROTOR BLADE
ABRASION STRIP TIP

BLADE PROFILE ABRASION STRIP NOTE 2 EROSION 0.40 INCH
(10.16 MM) MAXIMUM
SKIN TIP EROSION

0.30 INCH (7.62 MM)
CHORDWISE MAXIMUM
BALL. WEIGHT
NOTES:
1. END OF TAPE TO BE FLUSH WITH OUTBOARD END OF BLADE SKIN. TAPE
TO BE SYMMETRICAL ABOUT LEADING EDGE.
2. ABRASION TAPE MUST BE ALIGNED AT TOP PART OF BLADE.
G621006A
Figure 804. Installation/Replacement of Stainless Steel Abrasion Tape

(Main Rotor Blade Leading Edge)
Page 807
621000 Revision 20
MAINTENANCE MANUAL
30.00 INCH
(76.2 CM)
(REF)
12.00 INCH
(30.48 CM)
M504591 M504597
ABRASION TAPE 0.50 INCH ABRASION TAPE
(BOTTOM LAYER) (12.7 MM)
1.00 INCH
(2.54 CM)
1.00 INCH
(2.54 CM)
369D21100505 OR M504591 ABRASION 369D21105

369D21100509 MAIN TAPE (BOTTOM LAYER) OR
ROTOR BLADE ASSY 369D211053
ABRASION STRIP
7 ABRASION TAPE
1 ABRASION TAPE
NOTE
VIEW AA
NOTE: ABRASION TAPE MUST BE ALIGNED AT

TOP SURFACE OF BLADE.
G621007A
Figure 805. Installation/Replacement of Double Layer Abrasion Tape

(369D21100505 and 509 Rotor Blades)
Page 808
Revision 20 621000
MAINTENANCE MANUAL
(4). Remove backing and apply stainless MEK is flammable. Use in

steel abrasion tape to outboard leading WARNING well ventilated area and
edge of main rotor blade as follows: away from open flame.
(a). Apply 6.50 inch (16.5 cm) wide and (3). Clean areas to be sealed with clean
24 inch (61 cm) long abrasion tape cloth moistened with solvent (CM228).
along blade leading edge (Ref. For hard to clean problem areas, MEK
Figure 804) so tape overlaps bottom (CM219) may be used.
and top of blade edge equally or (Ref. (4). Prepare adhesive (CM404) per
Figure 805) for 369D21100505 and manufacturers instructions.
509 blades.
(5). Apply bead of adhesive to interface of
(b). Smooth and press abrasion tape into abrasion strip and blade skin. Ensure
place by hand. Use heat gun or there are no gaps or bridges in bead.
equivalent to maintain temperature.
(6). Cure adhesive per manufacturers
(c). Reapply pressure by hand following instructions.
initial installation to ensure proper
bonding. Abrasion tape must be free 11. Tip Cap Sealing
of surface wrinkles or air bubbles.
(Ref. Figure 805)
NOTE: A second abrasion tape may be applied
on top of the first tape to facilitate replace- Consumable Materials
ment when top tape becomes eroded. To ap- (Ref. Section 910000)
ply second tape, wipe surface of installed Item Nomenclature
strip clean with naptha aliphatic (CM220) CM212 Releasing agent
and repeat steps (3). and (4). above. Second CM213 Releasing agent
abrasion tape must be evenly aligned with
first at top surface of blade (Ref. Figure 804) CM318 Primer
for 369D21100 blades or (Ref. Figure 805) CM420 Sealant
for 369D21100505 and 509 blades. CM427 Sealing compound
10. Leading Edge Abrasion Strip Sealing
(1). Apply release agent (CM212 or CM213)
(Ref. Figure 805) to inside of tip cap per manufacturers
instructions.
Consumable Materials (2). Prepare and apply a 0.0100.020 inch
(Ref. Section 910000) (0.2540.508 mm) coating of sealant
Item Nomenclature (CM420, CM427 or CM428) to faying
surfaces per manufacturers instruc-
tions.
CM404 Adhesive, epoxy (3). Attach tip cap to blade and install
screw with primer (CM318).
(4). Wipe off squeezed out sealant flush

(1). Remove screw and tip cap from main with surface.
rotor blade.
NOTE: To inhibit moisture entering bond joint
(2). Remove any loose or cracked sealant or of abrasion strip after initial application,
adhesive from areas of main rotor reapply sealant, when sealant is worn away
blade. or becomes cracked.
Page 809
621000 Revision 34
MAINTENANCE MANUAL
C C A A
369A1116 TIP CAP

C
SEAL WITH
PR1436G, CLASS B2
OR
SEAL WITH EC2216 B/A FROM L.E. TO PR1422G, CLASS B
0.75 INCH (19.05 MM) DIM. ON T.E.
RADIUS (UPPER AND LOWER SURFACE) C
0.75 INCH 0.75 INCH

(19.05 MM) (19.05 MM)
369D21100 MAIN ROTOR BLADE ASSEMBLY
369D21105 ABRASION STRIP REF.

0.0030.005 INCH
369A1103 SKIN REF. TYP.
(0.07620.127 MM)
SEAL WITH
EC2216 B/A
369A1109501, 269A1186 0.010 INCH

BAL. WT. REF. (0.254 MM) SEAL SKIN / BAL. WT. ASSY
SEAL WITH TYP INTERFACE WITH EC2216 B/A
EC2216 B/A
AA TIP CAP OMITTED FOR CLARITY

0.12 INCH
(3.048 MM)
TYP
369D21105 ABRASION STRIP

369A1103 SKIN
CC TYP 2 PLACES SEAL SCREW BY
INSTALLING WITH
WET PRIMER
NAS51730
G621013A
Figure 806. Main Rotor Blade Abrasion Strip and Tip Cap Sealing
Page 810
Revision 20 621000
MAINTENANCE MANUAL
12. Main Rotor Blade Protective Tape NOTE: Tape must be of equal length on all
Installation blades to ensure proper balance.
In an effort to reduce the amount of erosion in (2). Cut tape long enough to cover erosion
the area inboard of the abrasion strip, MDHS plus approximately onehalf inch (12.7
has approved the installation of stainless steel mm) overlap on leading edge abrasion
or Mylar tape to the blade leading edge. strip.
Installation of the tape is optional.
(3). Round off square corners of tape to
The approved 3M Mylar tape, P/N 86711, is reduce peeling.
one inch (2.54 cm) wide and the 304 stainless
steel tape, P/N 87369D21104, is 0.027 inch (4). Lightly abrade faying surface of main
(0.6858 mm) thick and two inch (5.08 cm) rotor blade in area where tape is to be
wide. installed with 400grit abrasive paper
(CM801).
The length of the tape can vary, up to 8.0
inches (20.32 cm) in length, but must be equal (5). Wipe abraded area with naphtha
on all blades. aliphatic (CM220) to eliminate grease
and dirt film.
It is recommended to start with 2.5 inch (6.35
cm) length and increase the length as erosion (6). Treat any bare metal with epoxytype
occurs by replacing the tape. paint.
NOTE: NOTE: Do not allow temperature to exceed
D This installation is only approved on 120F (49C).
main rotor blades equipped with the 36
inch (91.44 cm) abrasion strips. (7). Using a heat gun, or equivalent, heat
abraded area.
D For installation of the Mylar tape, refer to
manufacturers instructions. Use of aero- (8). Apply aerosol primer to bonding area
sol primer Promoter 86 may be used to and allow to dry.
speed cure time of the tapes adhesive.
Mylar tape comes in rolls one inch (2.54 (9). Remove backing and apply tape to
cm) wide by 36 yards (329184 m) in length leading edge of blade.
and the promoter comes in 36 ounce
(1.065 L) cans. Mylar tape can be pur- (a). Apply tape so it overlaps each side of
chased from RS Hughes Company blade equally.
(18004538116). (b). Tape should overlap the inboard end
A. Stainless Steel Tape Installation of abrasion strip 0.5 0.03 inch (12.7
0.762 mm) at the leading edge of
blade.
(Ref. Section 910000) NOTE: Tape must be free of surface wrinkles or
Item Nomenclature air bubbles.
CM801 Abrasive paper, silicon carbide (10). Smooth and press tape into place by
hand.
Do not cut or trim tape after (11). Reapply pressure by hand following
CAUTION installation on blade, damage to initial installation to ensure proper
blade will occur. bonding.
(1). Measure length of eroded area on blade (12). Perform main rotor balance (Ref. Sec.
with the most erosion. 181000 or 181060).

621000 Revision 20
MAINTENANCE MANUAL
Section
622000
Main Rotor Hub
(369D/E/FF 500N)
MAINTENANCE MANUAL
MAIN ROTOR HUB

1. Main Rotor Hub General (3). Remove lockwire and disconnect
flexible boot from lower end of hub
The main rotor hub consists of a central hub, liner.
five identical pitch housings spaced 72 degrees
apart horizontally around the hub with (4). Disconnect each pitch control rod from
associated mechanisms and linkages. pitch housing.
Leadlag links, a leadlag damper, a droop (5). Disconnect scissors crank from main
stop striker strip and spacer, and a pitch rotor hub or scissors link.
control bearing with each pitch housing
produce the pivoting axis, blade flapping stop NOTE: To facilitate assembly, color code each
contact surfaces and leadlag hinge function pitch control rod to match pitch housing to
for the rotor blades. which it is attached.
Five laminated retention strap assemblies that (6). Remove two screws securing retainer to
are flexible both vertically and torsionally main rotor hub nut.
extend through the pitch housings and connect
to the leadlag links. (7). Remove nut retainer.
A lower shoe, attached to the central hub, (8). Using main rotor mast nut wrench
contains a droop stop ring and droop restrain- (ST701), remove nut from mast.
ers that support the blades at rest and
distribute droop loads at low blade rpm. (9). Using hub puller (ST702), break loose
main rotor hub (Ref. Figure 401).
The following instructions provide field Remove hub puller.
maintenance and repair procedures for the
main rotor hub. (10). Attach hoisting adapter, to eyebolts and
hoist hub from mast.
2. Main Rotor Hub Replacement B. Main Rotor Hub Installation
A. Main Rotor Hub Removal (Ref. Figure 402)
(Ref. Figure 401)
Special Tools Item Nomenclature
Item Nomenclature CM111 Grease, aircraft
ST201 Hoisting adapter CM115 Grease, oscillating bearing
ST701 Main rotor wrench assembly CM204 Compound, corrosion preventative
ST702 Hub puller CM702 Lockwire CRES
Special Tools
(1). Remove all main rotor blades. (Ref. Section 910000)
Item Nomenclature
(2). Remove main rotor drive shaft; then ST201 Hoisting adapter
reinstall hoisting eyebolts, washers and
nuts in rotor hub. Locate them to ST701 Main rotor wrench assembly
correspond with lugs of hoisting ST703 Main rotor hub driver
adapter (ST201).
Page 401
622000 Revision 36
MAINTENANCE MANUAL
Main rotor hub is a highly (5). Handpack hub cavity, between sleeve
CAUTION stressed component. Use ex- bushing and hub, with grease (CM111).
treme care to prevent it from striking any
object. Any impact damage may require re- (6). Place recessed spacer, recess down, on
placement of hub. top of sleeve bushing.
NOTE: (7). Handpack upper bearing cup and cone

with grease; then install cone on mast
D Removal of recessed spacer, upper bear- and use hub drive tool (ST703), to fully
ing cone, upper seal and seal retainer is seat cone.
not mandatory for installation of the
main rotor hub. If these items are in- (8). Fill remaining cavity to upper seal with
stalled, perform steps (1). thru (4). and grease.
(11). thru (22). Caution should be used
(9). Position upper seal in seal retainer
when installing hub to prevent damage to
with lip up; then press seal and retain-
these parts.
er in hub counterbore.
D If recessed spacer, upper bearing cone,
upper seal and seal retainer have been re- (10). Using a soft drift, carefully tap seal
moved, these parts should not be as- outer ring to seat in counterbore. Wipe
sembled in hub before installation of hub away any excess grease.
on helicopter. These items are reas-
(11). Apply grease (CM111) to exposed
sembled in hub after seating hub on mast.
threads on mast.
Prior to installing main rotor hub, insure
that all bearings are adequately serviced Be sure that seal is properly po-
with grease (CM111). CAUTION sitioned against seal retainer
D Replacement main rotor hubs do not come and that seal retainer does not pinch seal.
balanced from MDHS. If installing a re- Check by inserting a loop of approximately
placement hub, perform a main rotor hub 0.050 inch (1.27 mm) diameter lockwire,
balance (Ref. Sec. 181000, Main Rotor round feeler gage or other suitable tool with-
Hub Balance Procedure). out sharp edges between seal lip and retain-
er.
(1). Attach hoisting adapter (ST201) to
eyebolts in main rotor hub and connect NOTE: To insure that hub is seated onto mast
suitable hoist. properly before torquing, 2 4 threads
should be showing above the mast nut with
If hub assembly (with sleeve nut installed finger tight.
CAUTION bushing, spacer, upper bearing
(12). Install mast nut, using wrench (ST701);
and seal retainer installed) does not seat
torque nut to 200 footpounds (271
properly onto mast, do not attempt to force it
Nm). Apply coat of corrosion preventive
into position. Remove hub assembly from
compound (CM204) to screw holes in
mast and determine cause of hub not seat-
mast nut.
ing, correct the problem and follow the pro-
cedures for reinstallation. (13). Place retainer on nut and check
retainertonut screw hole alignment.
(2). Check that rotor mast is clean. Hoist
main rotor hub and position over mast; (14). Increase nut torque to not more than
then lower hub onto mast. 250 footpounds (339 Nm) to align
holes in retainer and nut.
NOTE: To inhibit mast corrosion when operat-
ing in salt water environment, lightly coat NOTE: If holes cannot be aligned in 200 250
bearing journals of mast with grease footpound (271 339 Nm) torque range,
(CM115). remove and invert nut and repeat proce-
dures in (12). thru (14). to align holes.
(3). Remove adapter, hoist and eyebolts.
(15). Secure retainer to nut with two screws;
(4). Check that hub is fully seated on mast. lockwire screws.
Page 402
Revision 20 622000
MAINTENANCE MANUAL
SLEEVE BUSHING
ROTOR HUB
OUTER LINER
SEAL JAW CONTACT

POINT
MAIN ROTOR PULLER

(ST702)
LIFT POINT
(TYPICAL 3 PLACES)
THRUST PAD
ROTOR MAST
ROTOR MAST
G622004A
Figure 401. Pulling Hub Assembly
Page 403
622000 Revision 20
MAINTENANCE MANUAL
Ensure that no washers are Excessive leadlag load applied

CAUTION used under screwheads and that CAUTION to the main rotor blades during
screwheads are free of burrs. ground handling can result in damage to the
(16). Verify that screwheads do not project damper assembly. Operators and mainte-
more than 0.020 inch (0.508 mm) above nance personnel should use extra caution to
hub upper surface, for adequate avoid leadlag loads in excess of 35 pounds
clearance between screwheads and (155.68 N) at the tip of the main rotor
driveshaft flange. blades.
NOTE:
(17). Connect scissors crank to main rotor D Refer to MDHS Notice DN45.2 for infor-
hub lower shoe and/or to scissors link. mation concerning required modification
of dampers produced prior to October
NOTE: Ensure pitch control rods are installed 1979. If leadlag dampers, P/N
at same locations from which removed. 369D21400501 are installed, they must
be modified to M50452 or be replaced
with P/N 369D21400503 dampers.
(18). Install five pitch control rods to pitch
housings (Ref. Sec. 623000, Pitch D If one or more main rotor blades strike an
Control Rod Replacement). object while rotating or the drive system
has been subjected to sudden stop, inspect
damper.
(19). Connect flexible boot to lower end of
rotor hub liner and secure with lock- 4. Main Rotor Damper Replacement
wire (CM702).
A. Main Rotor Damper Removal
(20). Install main rotor drive shaft (Ref. Sec. (1). Note and record location from which
631000). damper is to be removed from main
rotor hub.
(21). Install five main rotor blades. NOTE: At reinstallation, if damper is not rein-
stalled at same location, a check of and/or
(22). Perform main rotor blade droop angle blade phasing is required.
check if hub is new or replacement.
(2). Support blade parallel to ground.
(23). Perform main rotor hub balance (Ref. (3). Remove damper.
Sec. 181000, Main Rotor Hub
NOTE: If damper is to be reinstalled at same lo-
Balance Procedure) if a new or rebuilt
cation, do not disturb damper clevis, jam
hub is installed.
nuts or turnbuckle setting. Otherwise, blade
phasing is required at reinstallation of
3. Main Rotor Damper damper.
(4). If damper is not to be reinstalled,
(Ref. Figure 603) A main rotor damper is remove bushing from damper ear and
attached to each pitch housing of the rotor retain with hub.
hub. The damper is connected to the inboard
trailing edge of the associated main rotor blade B. Main Rotor Damper Installation
by an adjustable clevis to prevent lateral (1). Check, and if necessary, preset main
vibrations from occurring in main rotor blades. rotor damper length (Ref. Nominal
Neither damper travel nor stiffness is adjust- Damper Adjustment Procedure). Leave
able on the helicopter. Phasing of rotor blades jamnuts fingertight.
is affected by turnbuckle adjustment. Any
phasing problem caused by a defective damper NOTE: Ensure that bushing is installed in
should be corrected by replacing damper. large hole of damper ears.
Page 404
Revision 36 622000
MAINTENANCE MANUAL
(2). With damper rotational direction decal (2). Store all five dampers together in
facing outboard so it can be read, attach horizontal position for minimum of six
damper ears to pitch housing lug with hours. Preferred ambient temperature
bolt (head up), washers, and nut. during storage is 55 to 85F (13 to
Torque nut to 30 60 inchpounds 30C).
(3.39 6.78 Nm) and install cotter pin.
(3). Set damper length, centerlinetocent-
(3). Adjust main rotor blade phasing for erline of bolt attach holes, for initial
associated main rotor blade. installation.
369D/E
(4). After final phasing adjustments, torque 8.229 0.005 inch (209.017 0.127 mm)
jamnuts to 95 110 inchpounds 369F/FF
(10.73 12.43 Nm). Safety jamnuts to 8.132 0.005 inch (206.553 0.127 mm)
turnbuckle with new lockwire. Lock- 500N
wire must be located outboard, away 8.132 0.005 inch (206.553 0.127 mm).
from pitch housing.
(4). Install dampers on helicopter.
NOTE: Threaded end of damper turnbuckle
shaft must protrude through clevis base a NOTE: If ground rock or stick shake is noted,
minimum of two full threads and must clear complete following step.
blade damper attach fitting. (5). Length of damper may be adjusted
(5). Connect damper to blade. after initial setting by checking main
rotor system balance (Ref. Sec. 1810,
(6). Remove blade support. Main Rotor Balancing Procedure).
Check of main rotor system balance
5. Main Rotor Damper Nominal Adjustment should be accomplished only after main
rotor blades have been tracked.
(1). Remove all five main rotor blade
dampers from helicopter if installed. If more than four flats turn of
CAUTION turnbuckle adjustment is neces-
NOTE: If dampers are being replaced, do not sary to correct balance, return to step (1).
mix part numbers. and repeat procedure.
Page 405
622000 Revision 20
MAINTENANCE MANUAL
SCREW (2 PLACES)
(NOTE 2)
MAST
LOCKNUT
RETAINER
0.020 INCH (0.508 MM) RETAINER

LOCKWIRE
MAXIMUM SCREW HEAD
HEIGHT ABOVE HUB
SCREW
LOCKNUT
DRIVE SHAFT MAST SEAL
RETAINER SEAL RETAINER
SAFETYING
LOCKNUT AND SEAL
INSTALLATION
LOCKNUT
MAIN ROTOR
HUB
PITCH HOUSING
ASSEMBLY
SHIMS / SHIM WASHERS

(NOTE 4)
LOWER
SHOE
SHOULDERED BUSHING
PITCH
MAIN ROTOR MAST CONTROL
ROD
FLEXIBLE BOOT
NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A
NOTE 1 MINIMUM OF 0.010 INCH (0.254 MM) TO A
MAXIMUM OF 0.060 INCH (1.524 MM) ABOVE
ROTATING SWASHPLATE OUTSIDE SURFACE OF PART AFTER NUT IS
TIGHTENED.
2. IF LOCKNUT AND RETAINER SCREWHOLES
DO NOT MATCH WITHIN CORRECT TORQUE
RANGE, LOCKNUT IS TO BE INVERTED.
NOTE 3 3. WASHER(S) AS REQUIRED FOR BOLT END
TO SWASHPLATE BOOT CLEARANCE.
4. SHIMS / SHIM WASHERS USED TO FILL GAP
ON SHOULDERED BUSHING SIDE.
SCISSORS CRANK
G622005A
Figure 402. Main Rotor Hub Installation
Page 406
Revision 20 622000
MAINTENANCE MANUAL
MAIN ROTOR HUB

INSPECTION/CHECK
1. Main Rotor Hub Balancing General form of crescentshaped grooves. If
chafing wear exists, repair or replace.
(Ref. Sec. 1820) Main rotor hub balancing is Chafed area must be cleaned up before
accomplished by adding or removing weight measuring depth of damage to deter-
(flat washers) as required at the leadlag mine housing serviceability.
bolts. Analysis of main rotor hub balance is
accomplished using instrumentation that (3). Inspect droop stop ring for corrosion,
measures and localizes vibrations due to main dents and scratches. If defects are
rotor hub imbalance. Data provided by the found, repair or replace.
instrumentation is plotted on a chart designed
to indicate how much weight must be added or NOTE: To inhibit corrosion, spray droop stop
removed from the leadlag bolt. No other ring, rollers and pitch bearings with rust in-
means of balancing is to be used. hibitor (CM232).
(4). Inspect droop stop roller for flat spots,
2. Main Rotor Blade Phasing Check and/or
pit marks and looseness on roller shaft.
Adjustment
(5). Inspect striker plate for dents and pit
Main rotor blade phasing (alignment) is
marks that exceed 0.030 inch (0.762
necessary at damper installation or replace-
mm) depth. Damage exceeding this
ment, and may be necessary if there is ground
limit requires replacement of striker
rocking, or if onetoone lateral (main rotor)
plate.
vibration occurs during flight (Ref. Main Rotor
Damper Nominal Adjustment). (6). Press each pitch housing downward
several times and check for evidence of
3. Main Rotor Hub Inspection binding pitch bearing or droop restrain-
er follower. Inspect visible portion of
Consumable Materials droop restrainer for cracks and follower
(Ref. Section 910000) spring for breaks.
Item Nomenclature
NOTE: Do not remove tetrafluoroethylene
CM232 Rust inhibitor spray (TFE) debris which works out of pitch bear-
ing edge. Debris is normal and helps lubri-
cate bearing. Removal of debris increases
(1). Inspect pitch housing for scratches,
bearing wear rate.
nicks and cracks. No cracks are permis-
sible. Scratches and nicks must be (7). Use bright light and 5power magnify-
cleaned up before measuring depth of ing glass to inspect all main rotor hub
damage to determine housing service- leadlag links (Ref. Figure 802) for
ability. discoloration, pitting, intergranular
cracks or stress corrosion cracks. Any
(2). Inspect sleeve bushing for snug fit in
discoloration or pitting is evidence of
pitch housing arm clevis lug (Ref.
more than superficial corrosion and
Figure 805); lug must not show evi-
main rotor hub must be removed for
dence of wear caused by bushing
replacement of leadlag links.
movement. Maximum allowable
diameter for hole in bushed lug is NOTE: Normal or premature overhaul requires
0.5004 inch (12.71016 mm); for un- visual inspection plus dyepenetrant in-
bushed lug, not more than 0.3135 inch spection of links for same conditions.
(7.9629 mm). Inspect inner surfaces of
all pitch housing arm clevis lugs for (8). Inspection leadlag link stop for broken
chafing caused by misaligned pitch spring, cracks, breaks or visible bond
control rod end bearings. Chafing is in line cracks.
Page 601
622000 Revision 20
MAINTENANCE MANUAL
DAMAGE AREA
369D212715
LAMINATE
369D212713
LAMINATE
369D212717
LAMINATE
G622006
Figure 601. Strap Pack Lamination Exploded View
Page 602
Revision 20 622000
MAINTENANCE MANUAL
(9). Inspect interiors of leadlag bolts using (e). Reinstall screw, nut, washers and
bright light and 5X glass for cracks or balance hardware removed in step 2.
corrosion per LeadLag Bolt Inspection. Ensure hardware is installed exactly
as removed. Torque MS21042L08
(10). Inspect each striker strip for cracks, locknut on screw to 20 35 inch
deformation and badly worn contact pounds (2.26 3.95 Nm). Torque
surfaces. MS21042L3 locknut on screw to 30
(11). Inspect all parts of main rotor hub for Coat exposed screw threads, washers
cracks, breaks, scratches and nicks. and nut with sealant (CM420).
(Refer all questionable damage to
MDHI for disposition.) NOTE: Excessive amount of sealant can unbal-
ance rotor system. Apply light but thorough
(12). Inspect lower shoe scissors attach coat of sealant.
bearings for binding, looseness in bore
and wear. Maximum wear limits are (f). Install new cotter pin to secure nut to
0.010 inch (0.254 mm) radial and 0.020 leadlag bolt.
inch (0.508 mm) axial. NOTE: There are prebalanced rotor hubs in
service. Leadlag bolts of prebalanced hubs
(13). Inspect each of five main rotor reten- may contain balancing hardware. If so, re-
tion strap packs (Ref. Main Rotor Strap move balancing hardware to perform in-
Pack Lamination Inspection) at spection. Each set of removed hardware
specified intervals (Ref. Sec. 510). should be tagged or colorcoded to ensure
(Ref. MDHI Notices DN154 / EN44 / correct reinstallation.
FN33 for specific inspection require-
ments.) 5. Main Rotor Strap Pack Lamination
Inspection
4. LeadLag Bolt Inspection
CAUTION
Consumable Materials D Figure 601 and Figure 602 depict the
(Ref. Section 910000) main rotor hub and strap pack assembly
Item Nomenclature disassembled for clarity of location and
CM318 Primer area to be inspected for cracks. Under no
CM420 Sealant circumstances should the strap pack or
main rotor hub assembly ever be disas-
sembled in the field. MDHI and MDHI
(1). Inspect interiors of leadlag bolts using Approved Licensees are the only ap-
bright light and 5X glass for cracks or proved repair stations for main rotor hub
corrosion. assembly overhaul.
D If a hub assembly or strap pack assembly
(a). Remove cotter pin securing nut to (other than new parts in storage) are sub-
lower end of leadlag bolt. Do not jected to extended periods of nonuse,
disturb torque on nut or remove nut. whether installed on the helicopter or not,
the strap assembly should be inspected
(b). Remove screw, nut, washers and critically for corrosion and pitting before
balance hardware, if installed, from return to service. If corrosion is found on
leadlag bolt. the strap pack assemblies, contact MDHI
(c). Inspect bolt interior. Treat minor for disposition.
surface corrosion if noted. If corrosion D It is acceptable to operate a helicopter
pitting or cracks are noted remove with a hub assembly having a strap pack
and replace hub. with up to two failed laminates in any one
leg of the strap assembly. When a lami-
(d). Swab entire ID of bolt with primer nate in the strap assembly fails, the re-
(CM318). maining laminates pick up and carry the
Page 603
622000 Revision 29
MAINTENANCE MANUAL
load. This increased load causes slightly areas of the outboard shoes and pitch
more elongation in the remaining lami- housing assemblies.
nates of that leg thus shifting the mass of
the rotor system. Any time a vibration de- (5). Using a 10X magnifying glass, visually
velops or there is an increase in vibration inspect the edge of strap pack lami-
level over a short period of time, the main nates on both sides at outboard end of
rotor strap pack assembly should be in- blade pitch housing (area between
spected for cracked or failed laminates. outboard shoes).
NOTE: Conduct inspection indoors, if possible, (6). Use the following as acceptance/rejec-
or in a shaded area to eliminate glare of sun tion criteria for laminate inspection:
or bright outdoor light. To facilitate inspec-
tion, field fabricate and use plastic inspec- (a). A laminate has failed if cracked in
tion tool and wooden probe (Ref Figure 602). tongue area or in lead and lag legs of
the same laminate.
(1). Remove main rotor blades. (b). Reject strap pack and return hub
for overhaul when:
(2). If required, trim teflon from edges of
laminates using a aluminum chisel. 1). Three or more laminates in a
Fabricate from stock 0.250 x 6.00 x single strap pack have failed.
0.100 inch (6.35 x 152.4 x 2.54 mm).
Carefully scrape excess interlaminate 2). Three or more laminates in a
teflon sheets from both sides of strap single strap pack are cracked in
pack between top and bottom shoes at the same lead or lag leg.
outboard attachment bolt of all five
strap packs. 3). One laminate is cracked at the
outboard end in the area between
NOTE: outboard shoes (Ref. Figure 602).
D Do not pry at strap pack assemblies with 4). There are two or more gaps in the
sharp or hard edged tools. If edges become same strap pack. A single gap in
nicked or laminates get scratched, addi- any one strap pack assembly is
tional cracking can occur thus causing allowed.
hub replacement.
D Where accessible, ends of acceptable (7). Visually inspect strap pack assemblies
cracked or broken laminates should be for evidence of corrosion. If corrosion is
taped to prevent scratching and damag- found on strap pack laminates contact
ing of adjacent laminates. MDHI service department for disposi-
tion.
(3). (Ref. Figure 602) Field fabricate plastic (8). Using a bluntnosed wooden or pheno-
tool. Run plastic inspection tool in both lic pin, pencil size with 1/16 inch
directions along each laminate, feeling (1.5875 mm) radius point, probe at the
for a "catch" from a crack on a single upper and lower strap laminations at
laminate. Use the wooden or phenolic the outboard ends of the blade pitch
probe and probe at upper and lower end housings for evidence of laminate
of pack. Failed laminate in lead or lag failure. A failed laminate, either at the
will move away from the other lami- lead or lag end of the strap pack, will
nates. move away from the other laminates. If
the adjacent upper and lower laminates
(4). Using a light and mirror, visually remain in tension under the probing
inspect each of the main rotor strap operation, no laminate failures have
pack assemblies for evidence of cracks occurred. Refer to Step (5). Caution for
or breaks in strap pack laminates in the gap limitations.
Page 604
Revision 25 622000
MAINTENANCE MANUAL
ALL LAMINATES STRAIGHT,

NO GAPS.
DETAIL 1 ACCEPTABLE
ALL LAMINATES STRAIGHT. SINGLE GAP

EXISTING ADJACENT TO EITHER SHOE.
DETAIL 2 ACCEPTABLE
NOTE:
WHILE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES,
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THIS OCCURS, LOOK ALONG
EITHER SIDE IN AREA AA OR BB (DETAIL 3).
A A

EXISTING ANYPLACE WITHIN LAMINATES.
B B
DETAIL 3 ACCEPTABLE
REMOVE EXCESS TEFLON IN THIS AREA
G6220071
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2)
Page 605
622000 Revision 20
MAINTENANCE MANUAL
PLASTIC IN- WOODEN OR

1 SPECTION PHENOLIC
TOOL 0.125 INCH PROBE
LEAD LEG (3.175 MM)
LAMINATE HAS FAILED IF CRACK OCCURS

ON BOTH LEAD AND LAG LEGS OF SAME
LAMINATE. 0.250 INCH
(6.35 MM)
LAG LEG
2 LAMINATE HAS FAILED IF CRACK OCCURS

IN TONGUE OF LAMINATE (SHADED AREA
TONGUE SHOWN BEYOND JOINT OF STRAP PACK 6.00 INCH
LEGS). (15.24 CM)
1.5 INCH 4.00 INCH

(3.81 CM) 10.16 CM)
(REF)
TWO LAMINATE FAILURES AS DEFINED IN 1 1.00 INCH

AND/OR 2 ARE ALLOWED IN EACH STRAP (2.54 CM) 0.50 INCH
PACK ASSEMBLY. (TOTAL OF TEN LAMINATE (12.7 MM)
FAILURES PER HUB ASSEMBLY.)
0.0500.125 INCH
FIELD FABRICATION INSPECTION TOOLS (1.273.175 MM)
ALUMINUM CHISEL NOT SHOWN
(REF. TABLE 601, NOTE 2)
STRAP PACK IS REJECTED IF THREE OR MORE

4 LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED IN 1 AND/OR 2 ABOVE. 5

LAMINATES IN SAME PACK ARE CRACKED IN
THE LEG (LEAD OR LAG).
FAILED LAMINATE IF CRACK IS

FOUND ON EITHER EDGE OF
LAMINATE. IF ONE LAMINATE
HAS FAILED IN THIS AREA, RE-
PLACE HUB.
CAUTION:
DO NOT DISASSEMBLE STRAP PACK ASSEMBLY, 6
LAMINATIONS ARE SHOWN SEPARATED ONLY TO
DEPICT POSSIBLE CRACK LOCATIONS.
NOTE:
ANY CRACK IN LAMINATE IS CONSIDERED A BREAK.
THE LAMINATE HAS NOT FAILED HOWEVER, UNLESS
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK 1.50 INCH
IS LOCATED IN TONGUE AREA OF LAMINATE OR IS (3.81 CM)
UNDER SHOES (SEE DETAIL 6).
G6220072B
Page 606
Revision 20 622000
MAINTENANCE MANUAL
Table 601. Strap Pack Inspection

Replace or Return
Inspect Procedure (1) For Acceptable Hub for Overhaul
Outboard end. Visually. Use blunt nosed Failed laminates Two or less per Three or more laminate
wooden or phenolic probe (3). pack. failures in one pack.
(Figure 602). Probe at
upper and lower end of
pack. Failed laminate in
lead or lag leg will move
away from other
laminates.
Visually. Gaps between Single straight More than one gap

laminates. gap not exceed- found; gap exceeds
ing 0.030 inch acceptable limit.
(0.762 mm) within
pack or next to
either upper or
lower outer shoe.
Visually using light and Cracks or breaks. None. Cracks or breaks are
mirror (2). noted.
In area of and Visually with light and Cracks or breaks. Two or less Three or more laminate
within pitch mirror (2). laminate failures failures (2) in a pack;
housing assem- per strap pack (2). three or more laminates
blies. in pack with crack in
same leg (lead or lag).
Shims at each of Visually with light and Crack or break. Inspect top Top laminate is cracked
two attach mirror. laminate around in area of cracked or
points. shim (4). broken shim.
NOTES:
(1) Conduct visual inspections indoors or in shaded area to eliminate glare of sun or bright outdoor light.
(2) Removal of teflon covering is required for visual inspection of laminate edges. Use aluminum chisel,
fabricated from stock 0.025 x 6.00 x 0.100 inch (0.635 x 152.4 x 25.4 mm) to carefully scrape excess
interlaminate teflon sheets from both sides of strap pack between top and bottom shoes at outboard
attachment bolt of all five strap packs. Remove excess teflon from a point 1/2 inch (12.70 mm) outboard of
bolt centerline to 11/2 inches (38.1 mm) inboard of bolt centerline. Field fabricate and use plastic tool
(Ref. Figure 602). Run plastic tool in both directions along each laminate feeling for cracked laminate. Use
of plastic tool will ensure that shreds of teflon still hanging free does not obscure small cracks.
(3) Laminate has failed if crack is found in tongue area or if crack is found in both legs (lead and lag).
(4) Pay particular attention to shim installed at upper side of lead leg of each strap pack assembly. Maximum
of two shims may have been installed on top side of lead leg of strap pack to accommodate tolerance
buildup during strap pack assembly. If more than one shim is installed, pay particular attention to lower
shim when checking for cracks or breaks.
Page 607
622000 Revision 20
MAINTENANCE MANUAL
NOTE: Laminate failures are defined in step (1). Install cyclic lateral rigging fixture
(6). (ST506 or ST507), cyclic longitudinal
rigging fixture (ST504 or ST505), and
(9). Inspect upper, lower and center lami- collective rigging fixture (ST501 or
nates for cracks and breaks (Ref. ST502).
Figure 601).
(2). Rotate main rotor to position one blade
NOTE: Cracks, breaks or other noticeable dam- over tailboom.
age to the laminate/shims require main ro-
tor hub overhaul/replacement. (3). Raise and support other four blades
until four corresponding droop stop
(10). Install main rotor blades. rollers no longer contact their striker
plates.
(11). Perform tracking of main rotor blades
(Ref. Sec. 182000). (4). Place accurate propeller protractor on
top of main rotor drive shaft. Adjust
The maximum allowable bal- protractor to zero setting.
CAUTION ance weight per pitch case hous-
(5). Place protractor on machined surface of
ing on the main rotor hub assembly is 150
outboard end of blade pitch housing,
grams.
alongside leadlag bolthead. Measure
(12). Record location of all cracked/broken and record static droop angle.
laminates in helicopter Log Book (6). Repeat (2). thru (5). above for remain-
including strap serial number, blade ing blades.
color, leg, lead or lag, and laminate
position, if possible numbering from the (7). Maximum allowable static droop angle
top down. is six degrees. If measured droop angle
exceeds six degrees, inspect striker
6. Main Rotor Hub Droop Angle Check plate and roller for excessive wear and
adjust droop angle (Ref. Main Rotor
(Ref. Figure 805) Whenever new or replacement Hub Droop Angle Adjustment).
main rotor hub is installed or whenever excessive
droop angle is suspected, measure static droop 7. Main Rotor Damper and Attachments
angle of all five rotor blades. Droop angle must be Inspection
5.5 0.5 degrees.
Excessive leadlag load applied
CAUTION to the main rotor blades during
Special Tools ground handling can result in damage to the
(Ref. Section 910000) elastomeric damper buns and failure of the
Item Nomenclature damper assembly. Operators and mainte-
LeftHand Command: nance personnel should use extra caution to
avoid leadlag loads in excess of 35 pounds
ST501 Collective rigging fixture
(155.68 N) at the tip of the main rotor
(LH command)
blades.
ST504 Longitudinal rigging fixture
(LH command) (1). Inspect bearing in rotor blade and
ST506 Lateral rigging fixture bearing in the pitch housing for
(LH command) looseness around outer race. No degree
of radial or axial play is permitted.
RightHand Command
ST502 Collective rigging fixture (2). Inspect pitch housing and blade
(RH command) bearings for binding, galling, or scoring
ST505 Longitudinal rigging fixture in bore and for wear. No radial play is
(RH command) permitted. Maximum allowable axial
play is 0.015 inch (0.381 mm).
ST507 Lateral rigging fixture
(RH command) (3). Inspect clevis bushings for wear and
looseness.
Page 608
Revision 37 622000
MAINTENANCE MANUAL
(4). Inspect damper flange bushing for wear (2). Attach dial indicator or equivalent to
and play. outer case of damper; position indicator
arm on center aluminum disc as shown.
(5). Inspect lower bolt hole in damper
flange for wear. NOTE: Fabricate holding bar or fixture capable
of sustaining 100 pound (45.359 kg) static
(6). Inspect damper housing (including load (Ref. Figure 603).
flanges) for damage.
(3). Attach damper end cap to holding bar
(7). Inspect damper turnbuckle, jamnuts
or fixture.
and safetywire for security. No end play
is permitted when manually tested. NOTE: Perform weight loading and extension
NOTE: When performing leadlag of main ro- check at ambient temperature of 70 l0F
tor blades, apply rotor brake (if installed) or (21 5C). Apply total 100 pound (45.359
have assistant hold main rotor hub from kg) weight load to damper at one time, not in
moving. A second assistant is recommended weight increments.
to measure approximate damper extension (4). Using hydraulic jack or equivalent,
and compression. raise and attach 100 pound (45.359 kg)
(8). Leadlag each main rotor blade in turn weight load at damper clevis end.
to provide approximately 0.10 inch Slowly lower jack to avoid shock
(2.54 mm) extension and compression of loading. After period of two minutes
the damper elastomer. under load, measure damper extension
on dial indicator.
(9). Visually check each damper in turn for
cracks in elastomer or in elastomerto (5). If extension exceeds 0.056 inch (1.4224
metal bond at end face of damper: If mm) for M50452 damper, or 0.063 inch
bonding or elastomer cracks are noted, (1.6002 mm) for 369D21400503
measure depths of cracks, using depth damper, replace the damper assembly.
gage fabricated of shim stock or (6). Reinstall existing damper; or as
equivalent having a 0.20 inch (5.08 required; install replacement damper of
mm) indication. If depth of crack same type and part number (Ref. Main
exceeds 0.20 inch (5.08 mm), remove Rotor Damper Installation). Do not
and check damper. intermix PN 369D21400503 damper
8. Main Rotor Damper Weight Loading and with any other part number damper
Extension Check assemblies.
(Ref. Figure 603) NOTE: If replacement damper is installed, re-

cord part number, serial number, and other
(1). Remove damper assembly (Ref. Main pertinent information in Components Re-
Rotor Damper Removal). cord of helicopters Log Book.
Page 609
622000 Revision 20
MAINTENANCE MANUAL
ELASTOMER
(NOTE) MAIN ROTOR
DAMPER
ALUMINUM ELASTOMERTOMETAL
DISC BOND (NOTE)
END FACE MAIN ROTOR DAMPER
HOLDING BAR
OR FIXTURE
END CAP
DAMPER
CLAMP
INDICATOR
INDICATOR ARM
THREADED
SHAFT
CLEVIS
100 POUND (45.359 KG)

WEIGHT
NOTE:
CHECK ELASTOMER AND
ELASTOMERTOMETAL
BOND FOR CRACKS.
G622008A
Figure 603. Periodic Check of Main Rotor Damper Assembly
Page 610
Revision 20 622000
MAINTENANCE MANUAL
MAIN ROTOR HUB

REPAIRS
1. Main Rotor Retention Strap Pack Repair (2). After smoothing (removal of all sharp or
raised edges) repair depth must not
exceed 0.010 inch (0.254 mm) in any
Consumable Materials area of housing except inner surfaces of
(Ref. Section 910000) arm clevis lugs.
Item Nomenclature
(3). Maximum repair depth of 0.050 inch
CM725 Tape, electrical, plastic (1.27 mm) is acceptable in clevis lug
with sleeve bushing.
(Ref. Table 601) Where accessible, ends of
permissible cracks or broken laminates should (4). On opposite clevis lug repair depth of
be taped to prevent scratching and damaging 0.030 inch (0.762 mm) is permissible in
adjacent laminates. area of spot faces and maximum of
0.050 inch (1.27 mm) in area outside
Do not bend broken ends exces- spot faces.
CAUTION sively and scratch adjacent
straps. (5). Touch up repaired areas with chemical
film (CM206) followed by primer
(1). Carefully wipe ends of broken strap (CM318) and remove main rotor hub for
with a clean soft cloth moistened with pitch housing replacement.
solvent (CM234).
(2). Use mild blast of filtered air to dislodge 3. Unbushed Outboard Clevis Lug Hole
any foreign particles between broken Repair
strap ends and adjacent strap.
(3). Carefully tape broken ends of strap (Ref. Figure 801) Repair elongated outboard hole
with plastic electrical tape (CM725). in unbushed side of clevis lug if inside diameter of
hole exceeds 0.3135 inch (7.9629 mm).
2. Pitch Housing Repair

Item Nomenclature
(Ref. Section 910000) CM118 Grease
Item Nomenclature CM318 Primer
CM206 Chemical coating CM431 Sealing, locking and retaining compound
CM318 Primer
CM802 Abrasive cloth, aluminum oxide
(1). Remove existing bushing from inboard
lug.
During repair of pitch housing,
CAUTION comply with precautions for cov-
(2). Drill elongated hole in outboard lug to
ering engine air inlet fairing opening to pre-
0.3680 inch (9.3472 mm). Use drill
vent entry of foreign objects into air intake.
bushing as guide.
(1). Use grade 320 abrasive cloth (CM802)
to smooth scratches, nicks and chafing (3). Line ream hole to 0.37600.3770 inch
wear in pitch housing. (9.55049.5758 mm) diameter.
Page 801
622000 Revision 20
MAINTENANCE MANUAL
0.360 IN. (9.144 MM) MINI-

MUM WALL WIDTH
AROUND LUG (NOTE 1)
OUTBOARD LUG
PITCH HOUSING
OUTBOARD LUG
0.250 IN. (6.35 MM)
MINIMUM LUG WIDTH
(NOTE 1)
INBOARD LUG
0.220 IN.
(5.588 MM)
MINIMUM LUG
INBOARD LUG THICKNESS
(NOTE 1)
0.146 IN. (3.7084 MM) MINI-
MUM LUG THICKNESS AT
0.20 IN. (5.08 MM) SPOTFACE
LUG THICKNESS (NOTE 1)
(NOTE 1)
NOTES:
1. MAINTAIN MINIMUM WALL THICKNESS AROUND LUG AND MINIMUM
LUG THICKNESS FOR FIELD REPAIR OF CLEVIS LUG.
2. NO PAINT OR PRIMER PERMISSIBLE IN THIS AREA.
3. BRUSH CADMIUM PLATE GROUND SURFACE BEFORE INSTALLATION
IF POSSIBLE. IF NOT, COAT GROUND SURFACE THOROUGHLY WITH
PRIMER (CM318) AND INSTALL WHILE WET.
G6220121B
Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs (Sheet 1 of 2)
Page 802
Revision 34 622000
MAINTENANCE MANUAL
BUSHING 0.44 IN. (11.176 MM) O.D. X 0.25 IN. (6.35 MM) I.D. X 0.31 IN. (7.874 MM) LONG
BUSHING 0.75 IN. (19.05 MM) O.D. X 0.56 IN. (14.224 MM) I.D. X 0.31 IN. (7.874 MM) LONG
BOLT 0.25 IN. (6.35 MM) DIA X 1.38 IN. (3.5052 CM) LONG
WASHER 0.25 IN. (6.35 MM) I.D. X 0.75 IN. (19.05 MM) O.D. X 0.06 IN. (1.524 MM) THICK (2 EA.)
SECTION AA
1 REMOVAL OF HS610 SP 5010 R 313 X 290 SOLID BUSHING
DRILL BUSHING
0.49900.4995 INCH 0.37750.3780 INCH 1.13 INCH LONG
O.D. X
(12.674612.6873 MM) (9.58859.6012 MM) I.D. X (2.8702 CM)
0.37600.3770 INCH
REAMER (9.55049.5758 MM) DIA
DRILL NO. U 0.3689 INCH DIA

(9.37006 MM)
DRILL BUSHING
DRILL THEN REAM
0.875 INCH DRILL BUSHING
(22.225 MM) 0.375 X 0.250 X 0.31 IN.
(9.525 X6.35 X 7.874 MM) LONG 2 DRILL AND REAM OUTBOARD LUG
NOTE 2
BACK SPOTFACE
0.875 IN. (22.225 MM) DIA X TREAT SPOTFACE SURFACE AND REAMED
0.250 IN. (6.35 MM) DIA SHAFT HOLE WITH SEALING COMPOUND (CM431)
0.0200.030 INCH 0.0100.030 INCH

(0.5080.762 MM) FILLET RADIUS
(0.2540.762 MM)
0.146 INCH (3.7084 MM) MIN.
0.20 INCH (5.08 MM) MIN.
3 BACK SPOTFACE OUTBOARD LUG
AFTER INSTALLATION OF BUSHING,

SEAL EDGES WITH PRIMER (CM318).
FLANGE TO BE FLUSH WITH SURFACE. 369D213093 BUSHING
GRIND OFF TO 0.0000.015 IN. (0.0000.381 MM)
BELOW 0.75 IN. (19.05 MM) DIA. SPOTFACE
SURFACE (NOTE 3)
INSTALL WITH LOCTITE.
369D21306 SPLIT BUSHING, COAT WITH 0.0150.025 INCH

X 455 CHAMFER (TYP)
LUBRIPLATE (CM118) AT INSTALLATION. (0.3810.635 MM)
0.360 IN. 0.0000.015 INCH
0.8140.818 INCH (9.144 MM) MIN. (0.0000.381 MM)
(20.675620.7772 MM)
4 INSTALLATION OF 369D21306 AND 369D213093 BUSHINGS
G6220122B
Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs (Sheet 2 of 2)
Page 803
622000 Revision 20
MAINTENANCE MANUAL
NOTE: Check outboard lug two places for mini- 4. Pitch Control Bearing Housing Assembly,
mum wall thickness of 0.146 inch (3.7084 Spacer or Striker Strip Replacement
mm) and 0.20 inch (5.08 mm).
(Ref. Figure 802)
(4). Back spotface inside surface of outboard

lug to 0.875 inch (22.225 mm) diameter
and 0.0200.030 inch (0.5080.762 mm)
Item Nomenclature
depth. Use drill bushing as guide for
spotface pilot. Add chamfer to clear CM222 1,1,1Trichloroethane
bushing two places. CM425 Sealing compound
NOTE: Measure height of bushing and thick- (1). Support blade and pitch housing from
ness of lug prior to installation. Grind off beneath. Remove nuts. washers, and
end surface of bushing as required to secure bolts that secure bearing housing.
0.0000.015 inch (0.0000.381 mm) clear-
If droop shim washers are in-
ance. Brush cadmium plate ground end of CAUTION stalled between spacer and
bushing before installation. If equipment is
not available coat ground end thoroughly striker strip, they must be retained for rein-
with primer (CM318) and install while wet. stallation to establish correct static droop
If primer is used check for corrosion around angle between pitch housing and hub.
lug hole and bushing. (2). Carefully remove spacer by sliding it
downward past striker strip. Retain
(5). Install flanged bushing using loctite exact number of droop shim washers, if
(CM431). Use attach bolt or assembly installed.
pin as guide to ensure proper align- (3). Slide bearing housing assembly off
ment. Seal edges with loctite. pivot pin. Inspect pivot pin for grooving
or excessive wear.
(6). Install slotted bushing with grease
(CM118) in inboard lug.
(TFE) debris which works out of pitch bear-
NOTE: Check outboard and inboard lugs of cate bearing. Removal of debris increases
pitch control horn for interference with up- bearing wear rate.
per jamnut on pitch control rod. Use file or
(4). Remove and discard pitch bearing if
portable grinder to carefully trim off interf-
defective, total radial looseness of
ering corner of pitch housing lugs to provide
assembled ball and pivot pin must not
sufficient pitch control rod clearance. It is
exceed 0.010 inch (0.254 mm).
not necessary to trim to minimum wall
thickness. Do not exceed rework limitations. (5). Replace striker strip if it is cracked or
Touch up reworked area with chemical film leadlag contact areas are worn
and primer. Paint with matching color. through hard anodized surface.
(6). Remove sealant between pitch housing
(7). Reconnect pitch control rod assembly. and striker strip. use care not to scratch
Check for proper clearance between pitch housing. Remove striker strip
outboard lug and upper jamnut on pitch from pitch housing.
control rod.
(7). Cut old striker strip to facilitate
removal from retention strap assembly.
Use care during removal of Do not scratch strap assembly.
CAUTION parts from around strap pack.
Any nicks or scratches on straps require (8). Clean old sealant from pitch housing
scrapping of strap pack. using 1,1,1, trichloroethane (CM222).
Page 804
Revision 20 622000
MAINTENANCE MANUAL
(9). Cut out area of new striker strip (Ref. (1). Remove housing, striker plate and pitch
Figure 803). Deburr, smooth and radius control bearing.
cut edges.
(2). Place housing on drill press, striker
(10). Apply sealant (CM425) to faying surface down.
surfaces of the striker strip and pitch
housing. (3). Drill rivet hole out to 0.1920.198 inch
(4.87685.0292 mm) dia.
(11). Position pitch control bearing housing
on pivot pin (Ref. Figure 802). (4). Using a 0.453 inch (11.5062 mm) dia.
counterbore, counterbore rivet hole
If droop shim washers were re- 0.396 inch (10.0584 mm) deep.
CAUTION moved from between spacer and
striker strip, same exact thickness removed NOTE: The screwheld striker plate is dimen-
must be reinstalled. There must be an equal sionally thicker.
number of washers on each of all three bolts.
These washers establish correct static droop (5). Counterbore should have a 0.030 inch
between pitch housing and hub. (0.762 mm) radius. Deburr counterbore.
(12). Slide spacer into position between (6). Clean drilled and counterbored surfaces
bearing housing assembly and striker with solvent (CM234) and treat with
strip on pitch housing. Install exact chemical film (CM206).
thickness of droop shim washers
removed at time of disassembly. Align (7). Prime and paint counterbored surface
holes for all three bolts. with primer (CM318) and black paint
(CM305).
(13). Install bolts, washers and nuts; torque
(8). Reinstall pitch control bearing and
striker plate and reinstall housing.
Nm) and install safety wire.
(14). Seal all parting lines (joints) of the 6. Pitch Control Bearing Replacement
assembly with bead of sealing com-
pound (CM425). (Ref. Figure 802)
(15). Perform droop angle check (Ref. Main Consumable Materials

Rotor Hub Droop Angle Adjustment). (Ref. Section 910000)
Item Nomenclature
5. Pitch Control Bearing Housing CM206 Chemical coating
Modification
(Ref. Figure 802) To replace riveted striker plate CM318 Primer
with screw held striker plate, refer to following CM425 Sealing compound
instructions. CM803 Crocus cloth
Consumable Materials (1). To remove striker plate, remove screw,

(Ref. Section 910000) nut and washer or drill out rivets as
Item Nomenclature required. Discard striker plate if
CM206 Chemical coating brinnelling or pits exceed 0.030 inch
CM234 Solvent, drycleaning (0.762 mm) depth.
CM305 Lacquer, acrylic (2). Press bearing from housing bore. Clean
CM318 Primer any residual primer from housing bore
with MEK solvent (CM219).
Page 805
622000 Revision 20
MAINTENANCE MANUAL
CAUTION: WASHERS ARE INSTALLED BETWEEN SPACERS AND STRIKER

STRIP TO ESTABLISH CORRECT STATIC DROOP ANGLE BETWEEN HOUSING
AND HUB. EXACT NUMBER REMOVED MUST BE REINSTALLED. THREE PITCH
BEARING HOUSING BOLTS MUST EACH HAVE SAME NUMBER (THICKNESS) OF
WASHERS WHEN SHIMMING IS NECESSARY.
HUB
LEADLAG
BOLT LEADLAG
DROOP SHIM WASHERS LINKS
(SEE CAUTION)
SLEEVE
BUSHING
SPACER
PIVOT PIN
STRIKER STRIP
PITCH CONTROL BEAR-
ING HOUSING AS- MAIN ROTOR
SEMBLY STRAP PACK
PITCH BEARING HOUSING AND
SPACER INSTALLATION (CUR-
RENT CONFIGURATION)
ELONGATED HOLE LINE REAMED (USING

SLEEVE BUSHING AS GUIDE) TO PROVIDE 0.001
NOTE 1 NOTE 2 0.0015 IN. (0.02540.0381 MM) INTERFERENCE
LEADLAG FIT FOR 0.36750.3685 IN. (9.33459.3599 MM)
STOP OUTSIDE DIAMETER REPAIR BUSHING
LEADLAG LINK AND STOP
PITCH HOUSING ARM

(CLEVIS LUG) REPAIR BUSHING (2024T3 OR 7075T6
ALUMINUM PRESS FIT
PRESSFITTED REPAIR BUSHING LINE
DRILLED AND LINE REAMED USING SLEEVE
SLEEVE BUSHING AS GUIDE:
BUSHING FINAL ID; 0.31250.3135 IN. (7.93757.9629 MM)
PITCH HOUSING BUSHINGS REPAIR
NOTES: NOTES: (CONT)

1. FOR REMOVAL, WOOD DOWEL PLACED HERE AND 7. COUNTERSUNK RIVET HEAD OR SCREW HEAD MUST BE
STRUCK SHARPLY WITH HAMMER TO BREAK STOP BOND. FLUSH WITH HOUSING. UPSET END MUST BE FLUSH
2. ALL STOPTOLINK SHADED CONTACT SURFACES WITH PLATE.
BONDED WITH ADHESIVE (CM405 OR CM410). 8. UPSET END MUST BE FLUSH WITH PLATE.
3. INSTALL WITH WET PRIMER (CM318). 9. MANUFACTURED RIVET HEAD MUST BE FLUSH WITH
4. WET PRIMER (CM318) ON WASHER AND MATING SURFACES PLATE IN ALTERNATE RIVET INSTALLATION.
BEFORE INSTALLATION. 10. REPLACEMENT HOUSING FOR BOTH VERSIONS
5. NUT RETAINING BRACKET IS BONDED TO HUB. ATTACHED TO STRIKER PLATE WITH SCREW, WASHER
6. EARLY CONFIGURATION MODIFIED BY HUGHES SERVICE AND NUT FOR EASE OF REMOVAL.
NOTICE DN3.
G6220131A
Figure 802. Main Rotor Hub Components Repair and Installation (Sheet 1 of 2)
Page 806
Revision 20 622000
MAINTENANCE MANUAL
NOTE 7
HOUSING NOTE 10
SCREW
NUT WASHER
PITCH BEARING
NUT
STRIKER
PLATE
WASHER
THREADED
(2 PLACES)
COUNTERSUNK
HEAD SCREW
PITCH BEARING SUPPORT NUT

MODIFIED CONFIGURATION (RO-
INSTALLATION
TATED) (NOTE 6)
MAXIMUM ALLOWABLE WEAR IS 90%

CIRCUMFERENCE OF 0.4328 INCH
(10.99312 MM) MINIMUM DIAMETER 0.4328 INCH
(10.99312 MM)
MINIMUM DIA.
SPECIAL WASHER
NOTE 7 (NOTE 4)
HOUSING 0.125 INCH (3.175 MM)
MAXIMUM WEAR
NUT RETAINING
PITCH PIVOT PIN
BRACKET (NOTE 5)
(CURRENT CONFIGURATION)
(NOTE 3)
HUB
STRIKER
PLATE RETAINING NUT
BRACKET (NOTE 5)
ROUND HEAD RIV- CAPTIVE NUT EARLY CONFIGURATION
ET (NOTE 8)
MAXIMUM ALLOWABLE WEAR IS 90%

CIRCUMFERENCE OF 0.4328 INCH 0.4328 INCH
(10.99312 MM) MINIMUM DIAMETER (10.99312 MM)
PITCH
BEARING MINIMUM DIA.
PITCH PIVOT PIN 0.125 INCH (3.175 MM)
COUNTERSUNK HEAD RIVET (EARLY CONFIGURATION) MAXIMUM WEAR
(ALTERNATE) (NOTE 9) (NOTE 3)
EARLY CONFIGURATION
PIVOT PITCH PIN INSTALLATION
6220132A
Figure 802. Main Rotor Hub Components Repair and Installation (Sheet 2 of 2)
Page 807
622000 Revision 20
MAINTENANCE MANUAL
NOTE: Diameter of bearing bore, after cleanup, (1). Provide a backup support for link
should not exceed 1.1880 inch (3.01752 cm). assembly. Use 0.5 inch (12.7 mm) wood
Localized areas of clean up should not ex- dowel and hammer to drive stop from
ceed 0.003 inch (0.0762 mm) within an area link. Strike dowel sharply to break
of 25% of the circumference. adhesive bond.
(3). Rework minor surface abrasion in

housing bore by polishing with crocus (2). Using sharpedge metal scraper,
cloth (CM803). Restore chemical film carefully scrape any adhesive residue
(CM206), where removed. from link. If scraper penetrates through
paint and chemical surface film, surface
(4). Press bearing into bore using wet must be refinished. Depth of gouges or
primer (CM318). Wipe away any excess nicks is limited to 0.010 inch (0.254
primer using care to keep it out of mm) maximum after rework. Rework
bearing. Check teflon linings of bearing by smooth blending into surrounding
after installation to determine that no area with grade 320 abrasive cloth
damage occurred from pressing opera- (CM802). Final polish with crocus cloth
tion. (CM803). Restore chemical film protec-
tion (CM206).
NOTE: Ensure bearing is seated completely in
bore of housing and striker plate fits flush
on housing. (3). Clean bond area of all contact surfaces
by wiping with cleaner (CM228).
(5). Apply sealant (CM425) to faying Flushwipe cleaned surface four times
surfaces and install striker plate with with mixture of equal parts of distilled
screw, washer and nut or rivets. Head water and isopropyl alcohol (CM217) to
of countersunk screw or rivet must be remove all traces of phosphoric acid.
completely flush. Rinse cleaned surface with tap water,
followed by a rinse of distilled water
7. LeadLag Link Blade Stop Replacement until surface is "water break" free. Dry
for 30 minutes minimum at 150F
(Ref. Figure 802) Replace blade stop if it is (66C).
broken, cracked, has broken spring, or if there
are visible bond line cracks.
(4). Check fit of stop in link. Flange and
radius contact surfaces of stop must
Consumable Materials mate with link within 0.010 inch (0.254
(Ref. Section 910000) mm). Maximum clearance between stop
Item Nomenclature and inside surfaces of link ears is
CM206 Chemical coating limited to 0.020 inch (0.508 mm). This
CM217 Isopropyl alcohol tolerance applies to both sides of stop.
CM411 Adhesive, epoxy (5). Prepare mixture of epoxy adhesive
CM802 Abrasive cloth, aluminum oxide (CM411). Apply uniform coating of
CM803 Crocus cloth mixed adhesive to all contact surfaces.
Hand press stop into place between link
ears until all mating surfaces are in
Leadlag link assembly must firm contact. Apply a clamping device
CAUTION not be removed from pitch con- so that contact is maintained. Cure for
trol housing for this repair, since retention minimum of eight hours at room
bolt cannot be retorqued without special temperature, or two hours at 150F
adapter. (66C).
Page 808
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MAINTENANCE MANUAL
2.50 INCH
(6.35 CM)
CAUTION:
DO NOT SCRATCH STRAP PACK WHEN INSTALLING
THROUGH STRAP ASSY.
NOTE:
CUT OUT 0.250.50 IN. (6.3512.70 MM) PIECE OF THE 0.250.50 IN.
STRIKER STRIP BETWEEN LOWER BOLT HOLES. (6.3512.70 MM)
DEBURR AND RADIUS-CUT EDGES. (NOTE) G622009A
Figure 803. Striker Strip Replacement

8. Damper Attach Lug Bearing Replacement (4). Using 10power magnifying glass,
inspect fitting bore for cracks. No
cracks are permitted.
Item Nomenclature
(5). Measure fitting bore diameter. Accept-
able limits are 0.65480.6552 inch
CM216 Loctite remover (16.6319216.64208 mm).
CM318 Primer (6). Apply thin coat of primer (CM318) to
fitting bore.
Special Tools
(Ref. Section 910000) (7). Press bearing into fitting with arbor
Item Nomenclature press and fixture (ST706). Wipe away
excess primer.
ST706 Arbor press fixture
ST707 Staking tool (8). Stake bearing at both sides of fitting
with staking tool (ST707) in hydraulic
press with 60008000 pounds
(1). Use fly or circle cutter with 0.25 inch
(2668835584 N) of force. When staked,
(6.35 mm) pilot to remove staked lip
outer race of bearing shall be flush to
from one side of bearing without
not more than 0.010 inch (0.254 mm)
removing any material from fitting. If
above fitting surface (both sides). Gap
fitting is damaged by cutter, blade must
between staked lip of bearing race and
be replaced.
chamfered surface of fitting bore shall
(2). Use an arbor press to press bearing not exceed 0.002 inch (0.0508 mm) as
from fitting. checked with feeler gage. Staking
operation shall produce no cracks in
(3). Clean primer residue from fitting bore fitting or bearing.
with MEK (CM219). Remove locking
compound residue (if any) with locking (9). Fill staking gap (if any) with primer
compound remover (CM216). (CM318).
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MAINTENANCE MANUAL
9. LeadLag Bolt Corrosion Control NOTE: Torque pivot pin to 70 80 inch

pounds (7.91 9.04 Nm), then use 0.002
inch (0.0508 mm) feeler gage and check for
gap between pin flange and washer on
Item Nomenclature
mounting lug surface. No gap is allowed.
CM219 Methylethylketone (3). Install pivot pin in mounting lug with
CM318 Primer washer (Ref. Figure 802). Torque pivot
CM425 Sealing compound pin to 250 280 inchpounds (28.25
31.64 Nm). Apply sealant (CM420) at
junctures of pivot pin flange, washer
and hub.
Do not disturb torque on lead
CAUTION lag bolts. Special adapter is 11. Droop Stop Roller Repair or Replacement
needed to retorque leadlag bolts. (Ref. Figure 804) Replace defective droop stop
(1). Remove and tag or colorcode each set roller if clearance between roller bearing liner
of balance hardware that is installed. and shaft is more than 0.015 inch (0.381 mm).
Roller shaft outside diameter must not be less
(2). Remove corrosion with grade 180 than 0.4370 inch (11.0998 mm).
abrasive cloth (CM802) and finish with
grade 400 abrasive cloth. Consumable Materials
(3). Swab cleaned surface with MEK (Ref. Section 910000)
(CM219) and apply unthinned zinc Item Nomenclature
chromate primer (CM318). CM217 Isopropyl alcohol
(4). Reinstall original balance hardware

that was removed. Using sealant (1). Remove pitch control bearing housing
(CM425), reseal balance hardware. that contacts lower shoe roller to be
removed.
10. Pitch Control Bearing Pivot Pin Repair or
Replacement NOTE: Only one roller can be removed at one
time. Two opposing droop stop followers
(Ref. Figure 802) Minimum allowable pin must be pressed against droop stop ring to
diameter is 0.4328 inch (10.99312 mm). Pivot force opposite follower out and expose roller
pin grooving or excessive side wear may be shaft for removal. Same condition exists at
polished to original finish as long as minimum installation.
allowable pin diameter, 0.4328 inch (10.99312
mm), remains after rework. Replace any pin (2). Press down on pitch housing that is
requiring more rework as follows. opposite roller that is to be removed.
Remove cotter pin and shaft.
Consumable Materials (3). Remove droop stop roller.

(4). Wet down and clean plunger and
Item Nomenclature
mating shoe bushing with isopropyl
CM318 Primer alcohol (CM217).
CM420 Sealant
(5). To install replacement roller, press
down on pitch housings at opposite
(1). Remove pivot pin. sides of hub from roller to be installed.
Install roller, shaft and new cotter pin.
(2). Install replacement pivot pin wet with
primer (CM318). (6). Install pitch control bearing housing.
Page 810
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MAINTENANCE MANUAL
12. Droop Stop Ring Repair When Thead is free of ring channel,
turn it perpendicular (vertical) to
(Ref. Figure 804) channel.
NOTE: Followers can be easily rotated by use of
Consumable Materials nonmetallic drift in hole for droop stop roller
(Ref. Section 910000) shaft.
Item Nomenclature
CM103 Solid film lubricant
(6). Push droop stop ring toward number 4
and 5 followers. Pull number 2 follower
Thead from droop stop ring channel.
(1). Repair depth limit for corrosion, nicks When Thead is free of channel, turn it
or scratches in droop stop ring is 0.007 perpendicular to channel.
inch (0.1778 mm) for all surfaces except (7). Push droop stop ring toward number 1
outer edges of ring outer flanges. Depth and 5 followers. Pull number 3 follower
limit is 0.030 inch (0.762 mm). All Thead from droop stop ring channel.
reworked areas must be blended When Thead is free of channel, turn in
smoothly with 15 to 1 ratio into sur- perpendicular to channel.
rounding area.
(8). Tilt ring up on number 1, 2, and 3
(2). Spray repaired areas of rings with solid Theads as far as possible.
film lubricant (CM103).
(9). While pulling upward on ring, rotate (in
(3). Replace droop stop ring if repair limits succession) number 1, 2, and 3 Theads
are exceeded. so that they are out of, and below, droop
stop ring.
13. Droop Stop Ring Replacement
(10). Withdraw number 4 and 5 Theads
(Ref. Figure 804) from droop stop ring channel and
remove ring.
(1). With hub upside down, support hub so
When installing droop stop ring,
that pitch housings unload cam follow- CAUTION droop stop followers THeads
ers and provide maximum clearance
between striker plates and droop stop must be offset away from lower shoe to pre-
rollers. vent damage to lower shoe.
(11). Install replacement droop stop ring by
(2). Release retaining (snap) ring of each reversing removal procedure, steps (1).
droop stop restrainer from its groove. through (10)., making certain to
Move retaining ring flush against droop reinstall followers according to mark-
stop follower (Thead) to provide ings placed thereon prior to removal.
additional clearance and reduce spring
tension. (12). Compress follower spring and install
retaining (snap) ring in its groove on
(3). Remove five droop stop rollers. each follower.
(4). Starting from either scissors crank (13). Reinstall droop stop rollers.
attach lug, number all five droop stop
follower assemblies in clockwise 14. Droop Stop Follower (THead)
direction for location identification at Replacement
replacement. This number code should (Ref. Figure 804) Replace the droop stop
be placed on outer, upper end of plunger follower (Thead) if it is worn, scored or is
and on adjacent area of lower shoe. causing damage to the droop stop ring. After
Make sure codes are not accidentally the droop stop ring has been removed, the
removed during remaining steps. droop stop follower assemblies may be
removed from hub.
(5). Push droop stop ring toward number 3
and 4 followers. Pull number 1 follower (1). Remove droop stop follower assembly
Thead from droop stop ring channel. from hub.
Page 811
622000 Revision 37
MAINTENANCE MANUAL
(2). Remove pins that secure follower to (c). The maximum wear condition may
plunger. exist in one spot or in several spots
totaling 2.1 square inches (13.55
Droop stop followers THeads cm2).
CAUTION must be offset away from lower
shoe to prevent droop stop ring from damag- (6). Wet down and clean plunger and
ing lower shoe. mating shoe bushing with isopropyl
alcohol (CM217).
(3). Insert new follower. Thead must be at
right angle to roller shaft in plunger. (7). Install droop stop plunger into lower
shoe.
(4). Drill two 0.1560.158 inch
(8). Install roller, shaft and new cotter pin.
(3.96244.0132 mm) diameter holes
through follower in line with holes in (9). Complete droop stop ring installation.
plunger.
16. Main Rotor Hub Droop Angle Adjustment
(5). Insert pins and stake ends. No burrs or
roughness permissible after staking. (Ref. Figure 802) If static droop angle exceeds
six degrees, adjust as follows.
(6). Install follower assembly in hub.
(1). Remove main rotor blade.
(7). Reinstall droop stop ring. (2). Use flat washers of thickness required
to adjust spacing between spacer and
15. Droop Stop Plunger Removal, Inspection striker strip. Any one type, or combina-
and Installation tion, of correct part number washers
(Ref. Figure 804) (IPC) may be used; however, an identi-
cal washer selection must be installed
on each of three bolts that secure pitch
Consumable Materials control bearing assembly to pitch
(Ref. Section 910000) housing.
Item Nomenclature
(3). Remove nuts and washers and separate
CM217 Isopropyl alcohol spacer from striker strip. The use of one
0.016 inch washer raises static droop
(1). Remove droop stop ring. angle approximately onehalf degree.
Add sufficient washers to adjust droop
(2). Remove pitch control bearing housing angle within range of 5.5 0.5 degrees.
assembly that contacts the lower shoe Reinstall nuts and washers.
roller.
(4). If more than 0.063 inch (1.6002 mm)
(3). Remove cotter pin and shaft from droop spacing is required (above factory
stop follower assembly. spacing), inspect striker plate and
droop stop roller or follower and droop
(4). Remove droop stop roller. stop ring for excessive wear. Replace as
required.
(5). Check droop stop plunger for wear by
using the following criteria: NOTE: The average factory spacing on new and
rebuilt hubs is 0.063 inch (1.6002 mm).
(a). The minimum acceptable diameter
after wearing in service should be (5). Reinstall blade. Repeat measurement of
0.996 inch (25.2984 mm). static droop angle.
(6). As required, repeat above procedures
(b). The acceptable amount of wear for remaining blades.
though the anodized coating shall not
exceed 40% or 2.1 square inches (7). Following reinstallation or replacement
(13.55 cm2) of the total sliding of parts, check track of main rotor
surface area of the cylinder. blades.
Page 812
Revision 37 622000
MAINTENANCE MANUAL
LOWER
SHOE
PINS
DROOP STOP
0.007 INCH (0.1778 MM) PLUNGER DROOP STOP
MAX. DEPTH (15 TO 1 FOLLOWER
RADIUS) AFTER REWORK (THEAD) (NOTE)
COTTER
DROOP STOP PIN
SNAP RING
ROLLER
15 TO 1 SHAFT SPRING
RADIUS
DROOP STOP FOLLOWER INSTALLATION
0.007 INCH (0.1778 MM)

MAX. DEPTH (15 TO 1
0.030 IN. MAX. RADIUS) AFTER DROOP STOP RING
AFTER REWORK REWORK
DROOP STOP RING REPAIR LIMITS
DROOP STOP FOLLOWER

ASSEMBLY (5 PLCS)
SCISSORS CRANK
BEARING ROTATIONAL DRAG
ATTACH LUG
1.0 2.0 INLBS
LOWER SHOE INVERTED (0.113 0.226 NM)
NOTE: DROOP STOP FOLLOWER THEADS TO

BE OFFSET AWAY FROM LOWER SHOE. G622011C
Figure 804. Main Rotor Hub Assembly Repair
Page 813
622000 Revision 37
MAINTENANCE MANUAL
17. Main Rotor Hub Tapered Bearing Grease (4). Check bearing cup hub bore for scoring.
Repack, Inspection and Replacement Smooth out any roughness with grade
400600 abrasive cloth (CM802).
(Ref. Figure 805) Replace tapered roller Restore chemical film protection where
bearing cup or cone if it has any flat spots, removed. Maximum diameter of hub
scoring, pitting, grooving, discoloration (blue) bore for upper bearing cup (Ref.
or if it feels rough when rotated. Figure 805) is 4.4335 inch (11.26109
cm), measured in any direction.
Consumable Materials Maximum diameter of hub bore for
(Ref. Section 910000) lower bearing cup is 4.3095 inch
Item Nomenclature (10.94613 cm), measured in any
direction.
CM121 Preservation oil (5). Check upper seal retainer. No cracks,
sharp nicks or burrs are allowed. Minor
corrosion or other surface defects may
CM802 Abrasive cloth, aluminum oxide be polished out using crocus cloth
CM803 Crocus cloth (CM803). Grooving on seal contact
surfaces must not exceed 0.004 inch
Special Tools (0.1016 mm) depth after polishing.
Bearing cups are installed in
Item Nomenclature WARNING hub by differential tempera-
ST701 Main rotor wrench assembly ture (shrinkfit) method. Take appro-
priate precautions to prevent burns
when handling parts that are cooled to
Do not intermix Timken or NTN
CAUTION bearing cups and cones at upper
subzero temperatures.
and lower tapered roller bearing locations of (6). Place bearing cups in closed container
main rotor hub. of dry ice and cool for not less than 20
minutes to 40F (40C).
NOTE:
(7). Coat bore of hub with grease (CM111).
D Roller bearing cones and cups should al- Use care to maintain cuptohub bore
ways be replaced as a set. alignment and press cup into bore,
D Replace tapered roller bearing cup and using tools D and E (Ref. Figure 806),
cone if it has any flat spots, scoring, pit- until cup is seated.
ting, grooving, discoloration (blue) or if it
feels rough when rotated. (8). Apply film of grease to sleeve bushing.
Use pressing tool equivalent to tool C,
(1). Use pressing tools equivalent to items and press bearing cone onto sleeve
A and B (Ref. Figure 806) to press bushing.
upper and lower bearing cups from hub.
(9). With lip on center seal up, hand press it
A press ram of one to two tons is
into hub (Ref. Figure 805).
sufficient for removal.
(10). Apply film of grease on mast. Install
(2). Press lower bearing cone from sleeve preassembled sleeve bearing and
bushing. bearing cone on mast. Do not apply any
additional lubricant to roller bearing
In next step, do not spin reus-
CAUTION able bearings while cleaning.
set. Wipe any excess preservative oil
from bearing cone and cup.
Coat bearings lightly with oil (CM121) after
cleaning. (11). Place assembled hub over mast and
seat on lower roller bearing cone.
(3). Clean hub bore, sleeve bushing, seal
retainer and reusable bearings using (12). Install lead spacer 369A12245 (thick-
filtered solvent (CM234) spray. ness gage substitute for recessed
Page 814
Revision 21 622000
MAINTENANCE MANUAL
spacer) over mast. Rest spacer on top of pounds (1.13 1.69 Nm). This will be
sleeve bushing. 1.5 3 pounds (0.681 1.362 kg) on
spring scale used as in step (15). above.
NOTE: If lead spacer is not available, fabricate
its equivalent from lead sheet. Spacer di- (18). Remove hub and sleeve bushing with
mensions are; 2.96 inch (7.5184 cm) outside lower bearing cone from mast.
diameter; 2.68 inch (608072 cm) ID; (19). Position hub upsidedown. Handpack
0.0750.085 inch (1.9052.159 mm) thick. lower hub cavity (Ref. Figure 805) and
(13). Install upper bearing cone into hub and bearing cone on sleeve bushing with
on top of lead spacer. grease.
(20). Install sleeve bushing with bearing
(14). Install steel ring washer, equivalent to cone in hub. Handpack cavity between
tool F (Ref. Figure 806), as substitute bearing and hub liner with grease; then
for seal retainer (Ref. Figure 805). press in lower seal with seal lip toward
NOTE: Step (14). is not required. However, use top of hub. Wipe off excess grease.
of substitute washer for retainer prevents (21). Turn hub assembly right side up.
unnecessary scoring of retainer. Several
tightening and loosening actions may be re- (22). Complete reassembly of hub by install-
quired to get correct rotational drag on hub ing recessed spacer, upper bearing cone,
bearings. upper seal and seal retainer in hub at
installation of hub on mast.
(15). Install mast nut on mast using mast
nut wrench (ST701), tighten until 18. Main Rotor Hub Scissors Attach Lug
bearings are preloaded to 10 12 Bearing Replacement
inchpounds (1.13 1.36 Nm) of
rotational drag. Measure rotational Consumable Materials
drag using 0 10 pound (0 4.536 kg) (Ref. Section 910000)
spring scale hooked over one of hub Item Nomenclature
support web bosses, 6.5 inch (16.51 cm) CM206 Chemical coating
from hub centerline). A 1.50 1.75 CM216 Loctite remover
pound (0.681 0.7945 kg) pull with hub
CM304 Enamel, epoxy
in motion indicates correct rotational
drag. CM321 Surface primer locking compound
CM431 Sealing, locking and retaining compound
(16). Remove mast nut, tool F (Ref.
Figure 806), (or seal retainer), and
upper bearing cone. Remove lead spacer (1). Remove main rotor hub (Ref. Main
and measure compressed thickness. Rotor Hub Replacement).
Obtain serviceable recessed spacer of (2). Invert hub and place on work bench.
same thickness, or grind new recessed
spacer to required dimension. Discard (3). Remove droop stop ring (Ref. Droop
lead spacer after recessed spacer is Stop Ring Replacement).
correctly ground. (4). Press bearing from hub lug.
NOTE: To insure that hub is seated onto mast (5). Clean bearing bore with Loctite
properly before torquing, 2 4 threads remover (CM216).
nut installed finger tight. (6). Inspect bearing bore for nicks,
scratches and grooves.
(17). Install recessed spacer, recess down, on (7). Inspect bore for diameter of
top of sleeve bushing. Reinstall upper 0.65510.6556 inch (16.6395416.65224
bearing cone, seal retainer and mast mm).
nut. Torque nut to 200 250 foot
pounds (271 339 Nm) and check for (8). Touch up bearing bore with chemical
rotational drag of 10 15 inch coating (CM206).
Page 815
622000 Revision 35
MAINTENANCE MANUAL
(9). Apply surface primer (CM321) to room temperature or heat to 140

mating surfaces of bearing and bores 160F (60 72C) for one hour.
per manufacturers instructions.
(13). As required, touch up bearing lug with
NOTE: Do not allow primer to enter bearing. paint (CM304).
(10). Apply locking compound (CM431) to
(14). Check bearing for a noload rotational
faying surfaces of bearing and bore,
drag of 1.0 2.0 inchpounds (0.113
press bearing into bore while locking
0.226 Nm).
compound is wet.
(11). Remove excess sealant, do not allow (15). Reinstall droop stop ring (Ref. Droop
sealant to enter bearing. Stop Ring Replacement).
(12). Apply a small fillet of sealant around (16). Reinstall main rotor hub (Ref. Main
bearing and allow to dry for 24 hours at Rotor Hub Replacement).
Page 816
Revision 34 622000
MAINTENANCE MANUAL
STRIKER
STRIP
SEALANT
(NOTE 2)
PITCH BEARING
(NOTE 1)
PITCH (NOTE 1)
HOUSING
DROOP SHIM
WASHER (NOTE 9)
LAMINATED SPACER
STRAP PACK SEALANT STRIKER
(NOTE 2) PLATE
PITCH CONTROL DROOP RESTRAINER
BEARING HOUSING AND ROLLER
SEAL
(NOTE 4) UPPER BEARING CUP
(NOTE 10)
UPPER BEARING CONE
HUB (NOTE 10) SEAL RECESSED SPACER
RETAINER (NOTE 3)
SEAL
(NOTE 4)
PIVOT PIN SEALANT

(NOTE 2)
LOWER
SHOE
NOTE 1 NOTE 11
NOTES: DROOP STOP
1. HEAVY LINES INDICATE REINFORCED NOTE 5 RING
TEFLON BEARINGS (TYPICAL) SEAL
2. SEALANT (CM425) APPLIED TO LOCATIONS SHOWN. (NOTE 4) LOWER BEARING CUP
HUB OUTER
3. RECESSED SPACER SPECIALLY GROUND TO ESTABLISH CORRECT LINER (NOTE 10)
ROTATIONAL DRAG ON TAPERED BEARINGS, INSTALLED RECESS
DOWN ON TOP OF SLEEVE BUSHING.
4. SEAL TO BE UPWARD.
5. BEARING AND CAVITY TO BE FILLED WITH GREASE (CM111).
6. EARLY CONFIGURATION MODIFIED BY HUGHES SERVICE NOTICE DN3.
7. ON CURRENT CONFIGURATION, RIVET IS REPLACED BY SCREW, WASHER, AND NUT.
8. SEALANT (CM420) APPLIED TO SURFACES SHOWN.
9. DROOP SHIM WASHERS ARE INSTALLED AS REQUIRED TO OBTAIN PROPER ROTOR
DROOP ANGLE.
10. DO NOT INTERMIX TIMKEN AND NTN BEARING CUPS AND CONES AT UPPER AND LOWER
TAPERED BEARING LOCATIONS.
11. DROOP STOP FOLLOWER THEAD TO BE OFFSET AWAY FROM LOWER SHOE. G6220141B
Figure 805. Main Rotor Hub Cross Section (Sheet 1 of 2)
Page 817
622000 Revision 40
MAINTENANCE MANUAL
LEADLAG
PIVOT BOLT
LEADLAG SEALANT
LINKS (NOTE 2)
NOTE 2 NOTE 2
NOTE 1
COTTER PIN NOTE 7
RIVET
(NOTE 7)
EARLY CONFIGURATION
NOTE 8 MS21042L08
LOCKNUT MS21042L3 SUPPORT
LOCKNUT NOTE 8 NUT
WASHERS FOR
BALANCE AS
REQUIRED
STEP WASHER
WASHER
WASHER WASHER
LEAD LAG
PIVOT BOLT
SCREW SCREW
CURRENT CONFIGURATION EARLY CONFIGURATION

SERIAL NO. 0260D AND SUBS SERIAL NO. 003D THRU 0259D
G6220142A
Figure 805. Main Rotor Hub Cross Section (Sheet 2 of 2)
Page 818
Revision 40 622000
MAINTENANCE MANUAL
A A
2.875 IN. (7.3025 CM)

CUT OUT AFTER 0.50 IN. OUTSIDE DIAMETER
BEVELING (12.7 MM)
3.50 IN. (8.89 CM)

OUTSIDE DIAMETER
3.875 IN.
(9.8425 CM) 11.0 IN.
53 (27.94 CM)

5.75 IN.
3.375 IN. (14.605 CM)
0.375 IN. (8.5725 CM)
(9.525 MM)
0.1875 IN. (4.7625 MM) 0.203125 IN. (5.159375 MM)

4130 STEEL PLATE WALL STEEL PIPE WALL STEEL PIPE
A B C
4.40 IN. 4.30 IN.

(11.176 CM) (10.922 CM)
2.58 IN. 0.30 IN.
(6.5532 CM) (7.62 MM)
3.50 IN.
(8.89 CM)
2.0 IN. 2.0 IN.
(5.08 CM) (5.08 CM)
ALUMINUM ALLOY ALUMINUM ALLOY STEEL RING WASHER
D E F
TOOL USE:
A & B PRESS BEARING CUPS OUT OF HUB

C PRESS LOWER BEARING CONE ON SLEEVE BUSHING
D PRESS UPPER BEARING CUP INTO HUB
E PRESS LOWER BEARING CUP ONTO HUB
F IN PLACE OF UPPER SEAL RETAINER WHILE ADJUSTING ROTATIONAL DRAG
G HUB BEARING REMOVAL FABRICATION
G6220101
Figure 806. Tapered Bearing Tools Main Rotor Hub (Sheet 1 of 2)
Page 819
622000 Revision 37
MAINTENANCE MANUAL
7.0 INCH (17.78 CM)

SQUARED
4.75 INCH
(12.065 CM)
10.0 INCH (25.40 CM)

0.75 INCH SQUARED
MATERIAL: WOOD (19.05 MM) H6220102A
Page 820
Revision 37 622000
MAINTENANCE MANUAL
Section
622060
Main Rotor Hub
(600N)
MAINTENANCE MANUAL
MAIN ROTOR HUB

1. Main Rotor Hub General (3). Remove lockwire and disconnect
flexible boot from lower end of hub
(Ref. Figure 402) The main rotor hub consists liner.
of a central hub, six identical pitch housings
spaced 60 degrees apart horizontally around (4). Disconnect each pitch control rod from
the hub with associated mechanisms and pitch housing.
linkages. Leadlag links, a leadlag damper, a (5). Disconnect scissors crank from main
droop stop striker strip and spacer, and a pitch rotor hub or scissors link.
control bearing with each pitch housing
produce the pivoting axis, blade flapping stop NOTE: To facilitate assembly, color code each
contact surfaces and leadlag hinge function pitch control rod to match pitch housing to
for the rotor blades. Six laminated retention which it is attached.
strap assemblies that are flexible both
vertically and torsionally extend through the (6). Remove two screws securing retainer to
pitch housings and connect to the leadlag main rotor hub nut.
links. A lower shoe, attached to the central (7). Remove nut retainer.
hub, contains a droop stop ring and droop
restrainers that support the blades at rest and (8). Using main rotor mast nut wrench
distribute droop loads at low blade rpm. The (ST701), remove nut from mast.
following instructions provide field mainte-
nance and repair procedures for the main rotor (9). Using hub puller (ST702), break loose
hub. main rotor hub. Remove hub puller.
(10). Attach hoisting adapter (ST201), to
2. Main Rotor Hub Replacement eyebolts and hoist hub from mast.
A. Main Rotor Hub Removal B. Main Rotor Hub Installation

(Ref. Figure 402)
(Ref. Figure 401)
Special Tools (Ref. Section 910000)
Item Nomenclature CM111 Grease, aircraft
ST201 Hoisting adapter CM115 Grease, oscillating bearing
ST701 Main rotor wrench assembly CM204 Compound, corrosion preventative
ST702 Hub puller CM702 Lockwire CRES
Special Tools
(1). Remove main rotor blades. (Ref. Section 910000)
Item Nomenclature
(2). Remove main rotor drive shaft; then
reinstall hoisting eyebolts, washers and ST201 Hoisting adapter
nuts in rotor hub. Locate them to ST701 Main rotor wrench assembly
correspond with lugs of hoisting ST703 Main rotor hub driver
adapter (ST201).
Page 401
622060 Revision 36
MAINTENANCE MANUAL
Main rotor hub is a highly (5). Handpack hub cavity, between sleeve
CAUTION stressed component. Use ex- bushing and hub, with grease (CM111).
treme care to prevent it from striking any
object. Any impact damage may require re- (6). Place recessed spacer, recess down, on
placement of hub. top of sleeve bushing.
NOTE: (7). Handpack upper bearing cup and cone

with grease; then install cone on mast
D Removal of recessed spacer, upper bear- and use hub driver (ST703), to fully
ing cone, upper seal and seal retainer is seat cone.
not mandatory for installation of the
main rotor hub. If these items are in- (8). Fill remaining cavity to upper seal with
stalled, perform steps (1). thru (4). and grease.
(11). thru (22). Caution should be used
(9). Position upper seal in seal retainer
when installing hub to prevent damage to
with lip up; then press seal and retain-
these parts.
er in hub counterbore.
D If recessed spacer, upper bearing cone,
upper seal and seal retainer have been re- (10). Using a soft drift, carefully tap seal
moved, these parts should not be as- outer ring to seat in counterbore. Wipe
sembled in hub before installation of hub away any excess grease.
on helicopter. These items are reas-
(11). Apply grease (CM111) to exposed
sembled in hub after seating hub on mast.
threads on mast.
Prior to installing main rotor hub, insure
that all bearings are adequately serviced Ensure that seal is properly po-
with grease (CM111). CAUTION sitioned against seal retainer
D Replacement main rotor hubs do not come and that seal retainer does not pinch seal.
balanced from MDHS. If installing a re- Check by inserting a loop of approximately
placement hub, perform a main rotor sys- 0.050 inch (1.27 mm) diameter lockwire,
tem balance (Ref. Sec. 181060, Main round feeler gage or other suitable tool with-
Rotor System Balance Procedure). out sharp edges between seal lip and retain-
er.
(1). Attach hoisting adapter (ST201) to
eyebolts in main rotor hub and connect NOTE: To insure that hub is seated onto mast
suitable hoist. properly before torquing, two to four threads
If hub assembly (with sleeve nut installed finger tight.
CAUTION bushing, spacer, upper bearing
(12). Install mast nut, using wrench (ST701);
and seal retainer installed) does not seat
torque nut to 200 footpounds (271
properly onto mast, do not attempt to force it
Nm). Apply coat of corrosion preventive
into position. Remove hub assembly from
compound (CM204) to screw holes in
mast and determine cause of hub not seat-
mast nut.
ing, correct the problem and follow the pro-
cedures for reinstallation. (13). Place retainer on nut and check
retainertonut screw hole alignment.
main rotor hub and position over mast; (14). Increase nut torque to not more than
then lower hub onto mast. 250 footpounds (339 Nm) to align
holes in retainer and nut.
NOTE: To inhibit mast corrosion when operat-
ing in salt water environment, lightly coat NOTE: If holes cannot be aligned in 200 250
bearing journals of mast with grease footpound (271 339 Nm) torque range,
(CM115). remove and invert nut and repeat proce-
dures in (12). thru (14). to align holes.
(15). Secure retainer to nut with two screws;
(4). Check that hub is fully seated on mast. safety screws with lockwire (CM702).
Page 402
Revision 20 622060
MAINTENANCE MANUAL
MAIN ROTOR
PULLER
ROTOR HUB
6G62009A
Figure 401. Pulling Hub Assembly
Ensure that no washers are (21). Install main rotor blades.

CAUTION used under screw heads and
that screw heads are free of burrs.
(22). Perform main rotor blade droop angle
(16). Verify that screwheads do not project check if hub is new or replacement.
more than 0.020 inch (0.508 mm) above
hub upper surface, for adequate (23). Perform main rotor system balance
clearance between screw heads and (Ref. Sec. 181060, Main Rotor System
driveshaft flange. Balance Procedure) if a new or rebuilt
hub is installed.
(17). Connect scissors crank to main rotor
hub lower shoe and/or to scissors link.
3. Main Rotor Damper
NOTE: Ensure pitch control rods are installed
at same locations from which removed.
(Ref. Figure 603) A main rotor damper is
(18). Install pitch control rods to pitch attached to each pitch housing of the rotor
housings (Ref. Sec. 623060, Pitch hub. The damper is connected to the inboard
Control Rod Replacement). trailing edge of the associated main rotor blade
by an adjustable clevis to prevent lateral
(19). Connect flexible boot to lower end of vibrations from occurring in main rotor blades.
rotor hub liner and secure with lock- Neither damper travel nor stiffness is adjust-
wire (CM702). able on the helicopter. Phasing of rotor blades
is affected by turnbuckle adjustment. Any
(20). Install main rotor drive shaft (Ref. Sec. phasing problem caused by a defective damper
631000). should be corrected by replacing damper.
Page 403
622060 Revision 36
MAINTENANCE MANUAL
Excessive leadlag load applied NOTE: Ensure that bushing is installed in

CAUTION to the main rotor blades during large hole of damper ears.
elastomeric damper buns and failure of the (2). With damper rotational direction decal
damper assembly. Operators and mainte- facing outboard so it can be read, attach
nance personnel should use extra caution to damper ears to pitch housing lug with
avoid leadlag loads in excess of 35 pounds bolt (head up), washers, and nut.
(155.68 N) at the tip of the main rotor Torque nut to 30 60 inchpounds
blades. (3.39 6.78 Nm) and install cotter pin.
NOTE: If one or more main rotor blades strike (3). Adjust main rotor blade phasing for
an object while rotating or the drive system associated main rotor blade.
has been subjected to sudden stop, inspect
damper. (4). After final phasing adjustments, torque
jamnuts to 95 110 inchpounds
4. Main Rotor Damper Replacement (10.73 12.43 Nm). Safety jamnuts to
turnbuckle with new lockwire. Lock-
A. Main Rotor Damper Removal wire must be located outboard, away
from pitch housing.
(1). Note and record location from which
damper is to be removed from main NOTE: Threaded end of damper turnbuckle
rotor hub. shaft must protrude through clevis base a
minimum of two full threads and must clear
NOTE: At reinstallation, if damper is not rein-
blade damper attach fitting.
stalled at same location, a check of and/or
blade phasing is required. (5). Connect damper to blade.
(2). Support blade parallel to ground. (6). Remove blade support.
(3). Remove damper.
5. Main Rotor Damper Nominal Adjustment
NOTE: If damper is to be reinstalled at same lo-
cation, do not disturb damper clevis, jam (1). Remove main rotor blade dampers from
nuts or turnbuckle setting. Otherwise, blade helicopter if installed.
phasing is required at reinstallation of
(2). Store all dampers together in horizontal
damper.
position for minimum of six hours.
(4). If damper is not to be reinstalled, Preferred ambient temperature during
remove bushing from damper ear and storage is 55 to 85F (13 to 30C).
retain with hub.
(3). Set damper length, centerlinetocent-
B. Main Rotor Damper Installation erline of bolt attach holes, for initial
installation.
(1). Check, and if necessary, preset main 600N
rotor damper length (Ref. Nominal 8.132 0.005 inch (206.553 0.127 mm.
Damper Adjustment Procedure). Leave
jamnuts fingertight. (4). Install dampers on helicopter.
Page 404
Revision 36 622060
MAINTENANCE MANUAL
DRIVE SHAFT
SCREW AND
LOCKWIRE
RETAINER
RETAINER
LOCKNUT
LOCKNUT
MAIN ROTOR
HUB
LOCKNUT AND SEAL
INSTALLATION
SCREW LOCKWIRE
SHIMS/ RETAINER
SHIM WASHERS LOCKNUT
(NOTE 2)
SHOULDERED LOWER SHOE DRIVE

BUSHING SHAFT
MAIN ROTOR MAST

MAST
FLEXIBLE
BOOT SAFETYING
PITCH NOTE 1
CONTROL ROD
NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM SCISSORS
OF 0.010 INCH (0.254 MM) TO A MAXIMUM OF CRANK
0.060 INCH (1.524 MM) ABOVE OUTSIDE SURFACE
OF PART AFTER NUT IS TIGHTENED. ROTATING
2. SHIMS/SHIM WASHERS USED TO FILL GAP ON SWASHPLATE
SHOULDERED BUSHING SIDE. 6G62026
Figure 402. Main Rotor Hub Installation

622060 Revision 20
MAINTENANCE MANUAL
MAIN ROTOR HUB

INSPECTION/CHECK
1. Main Rotor System Balancing General (3). Inspect droop stop ring for corrosion,
dents and scratches. If defects are
Main rotor system balancing is accomplished found, repair or replace.
by adding or removing weight (flat washers) as NOTE: To inhibit corrosion, spray droop stop
required at the leadlag bolts. Analysis of ring, rollers and pitch bearings with spray
main rotor system balance is accomplished lubricant (CM104).
using instrumentation that measures and
localizes vibrations due to main rotor system (4). Inspect droop stop roller for flat spots,
imbalance. Data provided by the instrumenta- pit marks and looseness on roller shaft.
tion is plotted on a chart designed to indicate
how much weight must be added or removed (5). Inspect striker plate for dents and pit
from the leadlag bolt. No other means of marks that exceed 0.030 inch (0.762
balancing is to be used. If there is ground mm) depth. Damage exceeding this
rocking, or if oneperrev lateral (main rotor) limit requires replacement of striker
vibration occurs during flight refer to Sec. plate.
181060, Main Rotor System Balance (6). Press each pitch housing downward
Procedure. several times and check for evidence of
binding pitch bearing or droop restrain-
2. Main Rotor Hub Inspection er follower. Inspect visible portion of
droop restrainer for cracks and follower
spring for breaks.
(Ref. Section 910000) NOTE: Do not remove tetrafluoroethylene
Item Nomenclature (TFE) debris which works out of pitch bear-
CM104 Lubricant, spray cate bearing. Removal of debris increases
bearing wear rate.
(1). Inspect pitch housing for scratches, (7). Use bright light and 5power magnify-
nicks and cracks. No cracks are permis- ing glass to inspect all main rotor hub
sible. Scratches and nicks must be leadlag links (Ref. Figure 805) for
cleaned up before measuring depth of discoloration, pitting, intergranular
damage to determine housing service- cracks or stress corrosion cracks. Any
ability. discoloration or pitting is evidence of
more than superficial corrosion and
(2). Inspect sleeve bushing (Ref. Figure 805) main rotor hub must be removed for
for snug fit in pitch housing arm clevis replacement of leadlag links.
lug; if bushings are loose, remove and NOTE: Normal or premature overhaul requires
inspect. Inspect lug for evidence of wear visual inspection plus dyepenetrant in-
caused by bushing movement. Maxi- spection of links for same conditions.
mum allowable diameter for hole in
each lug is 0.4380 inch (11.13 mm). (8). Inspect leadlag link stop for broken
Inspect inner surfaces of all pitch spring, cracks, breaks or visible bond
housing arm clevis lugs for chafing line cracks.
caused by misaligned pitch control rod (9). Inspect interiors of leadlag bolts using
end bearings. Chafing is in form of bright light and 5X glass for cracks or
crescentshaped grooves. If chafing corrosion per LeadLag Bolt Inspection.
wear exists, repair or replace. Chafed
area must be cleaned up before measur- (10). Inspect each striker strip for cracks,
ing depth of damage to determine deformation and badly worn contact
housing serviceability. surfaces.
Page 601
622060 Revision 20
MAINTENANCE MANUAL
DAMAGED AREA
CUSHIONING
LAMINATE
CUSHIONING
LAMINATE
CUSHIONING
LAMINATE
6G62027
Figure 601. Strap Pack Lamination Exploded View
Page 602
Revision 20 622060
MAINTENANCE MANUAL
(11). Inspect all parts of main rotor hub for NOTE: Excessive amount of sealant can unbal-
cracks, breaks, scratches and nicks. ance rotor system. Apply light but thorough
(Refer all questionable damage to coat of sealant.
MDHI for disposition.)
(f). Install new cotter pin to secure nut to
(12). Inspect lower shoe scissors attach leadlag bolt.
bearings for binding, looseness in bore
and wear. Maximum wear limits are
0.010 inch (0.254 mm) radial and 0.020 4. Main Rotor Strap Pack Lamination
inch (0.508 mm) axial. Inspection
(13). Inspect each of six main rotor retention CAUTION

strap packs (Ref. Main Rotor Strap
Pack Lamination Inspection) at D Figure 601 and Figure 602 depict the
specified intervals (Ref. Section 0510). main rotor hub and strap pack assembly
disassembled for clarity of location and
3. LeadLag Bolt Inspection area to be inspected for cracks. Under no
circumstances should the strap pack or
Consumable Materials main rotor hub assembly ever be disas-
(Ref. Section 910000) sembled in the field. MDHI and MDHI
Item Nomenclature Approved Licensees are the only ap-
CM318 Primer proved repair stations for main rotor hub
assembly overhaul.
D If a hub assembly or strap pack assembly
(other than new parts in storage) are sub-
(1). Inspect interiors of leadlag bolts using jected to extended periods of nonuse,
bright light and 5X glass for cracks or whether installed on the helicopter or not,
corrosion. the strap assembly should be inspected
critically for corrosion and pitting before
(a). Remove cotter pin securing nut to return to service. If corrosion is found on
lower end of leadlag bolt. Do not the strap pack assemblies, contact MDHI
disturb torque on nut or remove nut. for disposition.
(b). Remove screw, nut, washers and D It is acceptable to operate a helicopter
balance hardware, if installed, from with a hub assembly having a strap pack
leadlag bolt. with one failed laminate in any one leg of
the strap assembly. When a laminate in
(c). Inspect bolt interior. Treat minor the strap assembly fails, the remaining
surface corrosion if noted (Ref. laminates pick up and carry the load. This
LeadLag Bolt Corrosion Control). If increased load causes slightly more elon-
corrosion pitting or cracks are noted gation in the remaining laminates of that
remove and replace hub. leg thus shifting the mass of the rotor sys-
(d). Swab entire ID of bolt with primer tem. Any time a vibration develops or
(CM318). there is an increase in vibration level over
a short period of time, the main rotor
(e). Reinstall screw, nut, washers and strap pack assembly should be inspected
balance hardware removed in step 2. for cracked or failed laminates.
Ensure hardware is installed exactly
as removed. Torque MS21042L08 NOTE: Conduct inspection indoors, if possible,
locknut on screw to 20 35 inch or in a shaded area to eliminate glare of sun
pounds (2.26 2.82 Nm). Torque or bright outdoor light. To facilitate inspec-
MS21042L3 locknut on screw to 30 tion, field fabricate and use plastic inspec-
60 inchpounds (3.39 6.78 Nm). tion tool and wooden probe (Ref Figure 602).
Coat exposed screw threads, washers
and nut with sealant (CM425). (1). Remove main rotor blades.
Page 603
622060 Revision 33
MAINTENANCE MANUAL
ALL LAMINATES STRAIGHT,

NO GAPS.
DETAIL 1 ACCEPTABLE

EXISTING ADJACENT TO EITHER SHOE.
DETAIL 2 ACCEPTABLE
NOTE:
WHILE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES,
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THIS OCCURS, LOOK ALONG
EITHER SIDE IN AREA AA OR BB (DETAIL 3).
A A

EXISTING ANYPLACE WITHIN LAMINATES.
B B
DETAIL 3 ACCEPTABLE
REMOVE EXCESS TEFLON IN THIS AREA
6G620781
Page 604
Revision 20 622060
MAINTENANCE MANUAL
PLASTIC WOODEN OR
1 PHENOLIC PROBE
INSPECTION TOOL
0.125 INCH
(3.175 MM)
LEAD LEG
LAMINATE HAS FAILED IF CRACK OCCURS
ON BOTH LEAD AND LAG LEGS OF SAME
LAMINATE. 0.250 INCH
(6.35 MM)
LAG LEG
2 LAMINATE HAS FAILED IF CRACK OCCURS

IN TONGUE OF LAMINATE (SHADED AREA
TONGUE SHOWN BEYOND JOINT OF STRAP PACK 6.00 INCH
LEGS). (15.24 CM)
4.00 INCH
1.5 INCH 10.16 CM)
(3.81 CM)
(REF)
ONE LAMINATE FAILURE AS DEFINED IN 1 1.00 INCH

AND/OR 2 ARE ALLOWED IN EACH STRAP 0.50 INCH
PACK ASSEMBLY. (TOTAL OF SIX LAMINATE (2.54 CM)
(12.7 MM)
FAILURES PER HUB ASSEMBLY.)
0.0500.125 INCH
FIELD FABRICATION INSPECTION TOOLS (1.273.175 MM)
ALUMINUM CHISEL NOT SHOWN
(REF. TABLE 601, NOTE 2)
STRAP PACK IS REJECTED IF TWO OR MORE

4 LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED IN 1 AND/OR 2 ABOVE. 5

LAMINATES IN SAME PACK ARE CRACKED IN
THE LEG (LEAD OR LAG).
FAILED LAMINATE IF CRACK IS

FOUND ON EITHER EDGE OF
LAMINATE. IF ONE LAMINATE
HAS FAILED IN THIS AREA,
REPLACE HUB.
CAUTION:
DO NOT DISASSEMBLE STRAP PACK ASSEMBLY,
LAMINATIONS ARE SHOWN SEPARATED ONLY TO
DEPICT POSSIBLE CRACK LOCATIONS.
NOTE:
ANY CRACK IN LAMINATE IS CONSIDERED A BREAK. 1.50 INCH
THE LAMINATE HAS NOT FAILED HOWEVER, UNLESS (3.81 CM)
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK
IS LOCATED IN TONGUE AREA OF LAMINATE OR IS
UNDER SHOES (SEE DETAIL 6). 6G620782B
Page 605
622060 Revision 34
MAINTENANCE MANUAL
Table 601. Strap Pack Inspection

Replace or Return
Inspect Procedure (1) For Acceptable Hub for Overhaul
Outboard end. Visually. Use blunt nosed Failed laminates One or less per Two or more laminate
wooden or phenolic probe (3). pack. failures in one pack.
(Figure 602). Probe at
upper and lower end of
pack. Failed laminate in
lead or lag leg will move
away from other
laminates.
Visually. Gaps between Single straight More than one gap

laminates. gap not exceed- found; gap exceeds
ing 0.03 inch acceptable limit.
(0.762 mm) within
pack or next to
either upper or
lower outer shoe.
Visually using light and Cracks or breaks. None. Cracks or breaks are
mirror (2). noted.
In area of and Visually with light and Cracks or breaks. One or less Two or more laminate
within pitch mirror (2). laminate failures failures (2) in a pack;
housing assem- per strap pack (2). two or more laminates
blies. in pack with crack in
same leg (lead or lag).
Cushioning Visually with light and Crack or break. None Cracks or breaks are
laminates at mirror. noted.
each of two
attach points.
NOTES:
(1) Conduct visual inspections indoors or in shaded area to eliminate glare of sun or bright outdoor light.
(2) Removal of teflon covering is required for visual inspection of laminate edges. Use aluminum chisel,
fabricated from stock 0.025 x 6.00 x 0.100 (6.35 x 152.4 x 25.4 mm) to carefully scrape excess
interlaminate teflon sheets from both sides of strap pack between top and bottom shoes at outboard
attachment bolt of all six strap packs. Remove excess teflon from a point 0.50 inch (12.7 mm) outboard of
bolt centerline to 1.50 inches (38.1 mm) inboard of bolt centerline. Field fabricate and use plastic tool (Ref.
Figure 602). Run plastic tool in both directions along each laminate feeling for cracked laminate. Use of
plastic tool will ensure that shreds of teflon still hanging free does not obscure small cracks.
(3) Laminate has failed if crack is found in tongue area or if crack is found in both legs (lead and lag).
Page 606
Revision 33 622060
MAINTENANCE MANUAL
(2). If required, trim teflon from edges of (6). Use the following as acceptance/rejec-
laminates using a aluminum chisel. tion criteria for laminate inspection:
Fabricate chisel from stock, 0.250 x 6.00
x 0.100 inch (6.35 x 152.4 x 25.4 mm). (a). A laminate has failed if cracked in
Carefully scrape excess interlaminate tongue area or in lead and lag legs of
teflon sheets from both sides of strap the same laminate.
pack between top and bottom shoes at
(b). Reject strap pack and return hub
outboard attachment bolt of all six
for overhaul when:
strap packs.
NOTE: 1). Two or more laminates in a single
strap pack have failed.
D Do not pry at strap pack assemblies with
sharp or hard edged tools. If edges become 2). Two or more laminates in a single
nicked or laminates get scratched, addi- strap pack are cracked in the same
tional cracking can occur thus causing lead or lag leg.
hub replacement.
3). One laminate is cracked at the
D Where accessible, ends of acceptable outboard end in the area between
cracked or broken laminates should be outboard shoes (Ref. Figure 602).
taped to prevent scratching and damag-
ing of adjacent laminates. 4). There are two or more gaps in the
(3). (Ref. Figure 602 for field fabricate same strap pack. A single gap in
plastic tool) Run plastic inspection tool any one strap pack assembly is
in both directions along each laminate, allowed.
feeling for a catch from a crack on a (7). Visually inspect strap pack assemblies
single laminate. Use the wooden or for evidence of corrosion. If corrosion is
phenolic probe and probe at upper and found on strap pack laminates contact
lower end of pack. Failed laminate in MDHI service department for disposi-
lead or lag will move away from the tion.
other laminates. If the adjacent upper
and lower laminates remain in tension (8). Inspect upper, lower and center cush-
under the probing operation, no ioning laminates for cracks and breaks
laminate failures have occurred. (Ref. Figure 601).
(4). Using a light and mirror, visually NOTE: Cracks, breaks or other noticeable dam-
inspect each of the main rotor strap age to the cushioning laminates require
pack assemblies for evidence of cracks main rotor hub overhaul/replacement.
or breaks in strap pack laminates in the
areas of the outboard shoes and pitch (9). Record location of all cracked/broken
housing assemblies. laminates in Helicopter Log Book
including strap serial number, blade
(5). Using a 10X magnifying glass, visually color, leg (lead or lag) and laminate
inspect the edge of strap pack lami- position, if possible, numbering from
nates on both sides at outboard end of the top down.
blade pitch housing (area between
outboard shoes). (10). Install main rotor blades.
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622060 Revision 33
MAINTENANCE MANUAL
5. Main Rotor Hub Droop Angle Check (7). Maximum allowable static droop angle
is six degrees. If measured droop angle
(Ref. Figure 805) Whenever new or replacement exceeds six degrees, inspect striker
main rotor hub is installed or whenever excessive plate and roller for excessive wear and
droop angle is suspected, measure static droop adjust droop angle (Ref. Main Rotor
angle of all six rotor blades. Droop angle must be Hub Droop Angle Adjustment).
5.5 0.5 degrees.
6. Main Rotor Damper and Attachments
Inspection
Special Tools
(Ref. Section 910000) Excessive leadlag load applied
Item Nomenclature CAUTION to the main rotor blades during
ST206 Prop protractor ground handling can result in damage to the
LeftHand Command:
damper assembly. Operators and mainte-
ST501 Collective rigging fixture nance personnel should use extra caution to
(LH command) avoid leadlag loads in excess of 35 pounds
ST504 Longitudinal rigging fixture (155.68 N) at the tip of the main rotor
(LH command) blades.
(LH command)
(1). Inspect bearing in rotor blade and
bearing in the pitch housing for
RightHand Command looseness around outer race. No degree
ST502 Collective rigging fixture of radial or axial play is permitted.
(RH command)
ST505 Longitudinal rigging fixture (2). Inspect pitch housing and blade
(RH command) bearings for binding, galling, or scoring
in bore and for wear. No radial play is
ST507 Lateral rigging fixture permitted. Maximum allowable axial
(RH command) play is 0.015 inch (0.381 mm).
(3). Inspect clevis bushings for wear and
(1). Install cyclic lateral rigging fixture looseness.
(ST506 or ST507), cyclic longitudinal
rigging fixture (ST504 or ST505), and (4). Inspect damper flange bushing for wear
collective rigging fixture (ST501 or and play.
ST502).
(5). Inspect lower bolt hole in damper
(2). Rotate main rotor to position one blade flange for wear.
over tailboom. (6). Inspect damper housing (including
(3). Raise and support other five blades flanges) for damage.
until five corresponding droop stop (7). Inspect damper turnbuckle, jamnuts
rollers no longer contact their striker and safetywire for security. No end play
plates. is permitted when manually tested.
(4). Place accurate prop protractor (ST206) NOTE: When performing leadlag of main ro-
on top of main rotor drive shaft. Adjust tor blades, apply rotor brake (if installed) or
protractor to zero setting. have assistant hold main rotor hub from
moving. A second assistant is recommended
(5). Place protractor on machined surface of to measure approximate damper extension
outboard end of blade pitch housing, and compression.
alongside leadlag bolthead. Measure
and record static droop angle. (8). Leadlag each main rotor blade in turn
to provide approximately 0.10 inch
(6). Repeat (2). thru (5). above for remain- (2.54 mm) extension and compression of
ing blades. the damper elastomer.
Page 608
Revision 20 622060
MAINTENANCE MANUAL
(9). Visually check each damper in turn for (3). Attach damper end cap to holding bar
cracks in elastomer or in elastomerto or fixture.
metal bond at end face of damper: If
bonding or elastomer cracks are noted, NOTE: Perform weight loading and extension
measure depths of cracks, using depth check at ambient temperature of 70 l0F
gage fabricated of shim stock or (21 5C). Apply total 100 pound (45.359
equivalent having a 0.20 inch (5.08 kg) weight load to damper at one time, not in
mm) indication. If depth of crack weight increments.
exceeds 0.20 inch (5.08 mm), remove (4). Using hydraulic jack or equivalent,
and check damper. raise and attach 100 pound (45.359 kg)
weight load at damper clevis end.
7. Main Rotor Damper Weight Loading and Slowly lower jack to avoid shock
Extension Check loading. After period of two minutes
under load, measure damper extension
(Ref. Figure 603)
on dial indicator.
(1). Remove damper assembly (Ref. Main (5). If extension exceeds 0.063 inch (1.6002
Rotor Damper Removal). mm), replace the damper assembly.
(2). Attach dial indicator or equivalent to (6). Reinstall existing damper; or as
outer case of damper; position indicator required; install replacement damper.
arm on center aluminum disc as shown.
NOTE: If replacement damper is installed, re-
NOTE: Fabricate holding bar or fixture capable cord part number, serial number, and other
of sustaining 100 pound (45.359 kg) static pertinent information in Components Re-
load (Ref. Figure 603). cord of helicopters Log Book.
Page 609
622060 Revision 25
MAINTENANCE MANUAL
ELASTOMER
(NOTE) MAIN ROTOR
DAMPER
ALUMINUM ELASTOMERTOMETAL
DISC BOND (NOTE)
END FACE MAIN ROTOR DAMPER
HOLDING BAR
OR FIXTURE
END CAP
DAMPER
CLAMP
INDICATOR
INDICATOR ARM
THREADED
SHAFT
CLEVIS
100 POUND (45.359 KG)

WEIGHT
NOTE:
CHECK ELASTOMER AND
ELASTOMERTOMETAL
BOND FOR CRACKS.
G622008A
Figure 603. Periodic Check of Main Rotor Damper Assembly
Page 610
Revision 20 622060
MAINTENANCE MANUAL
MAIN ROTOR HUB

REPAIRS
1. Main Rotor Retention Strap Pack Repair If droop shim washers are in-
CAUTION stalled between spacer and
Where accessible, ends of permissible cracks or striker strip, they must be retained for rein-
broken laminates (Ref. Table 601) should be stallation to establish correct static droop
taped to prevent scratching and damaging angle between pitch housing and hub.
adjacent laminates.
(2). Carefully remove spacer by sliding it
downward past striker strip. Retain
Consumable Materials exact number of droop shim washers, if
(Ref. Section 910000) installed.
Item Nomenclature
(3). Slide bearing housing assembly off
pivot pin. Inspect pivot pin for grooving
CM725 Tape, electrical, plastic or excessive wear.
Do not bend broken ends exces- (TFE) debris which works out of pitch bear-
CAUTION sively and scratch adjacent ing edge. Debris is normal and helps lubri-
straps. cate bearing. Removal of debris increases
bearing wear rate.
(1). Carefully wipe ends of broken strap
with a clean soft cloth moistened with (4). Remove and discard pitch bearing if
solvent (CM234). defective, total radial looseness of
assembled ball and pivot pin must not
(2). Use mild blast of filtered air to dislodge exceed 0.010 inch (0.254 mm).
any foreign particles between broken
strap ends and adjacent strap. (5). Replace striker strip if it is cracked or
leadlag contact areas are worn
(3). Carefully tape broken ends of strap through hard anodized surface.
with plastic electrical tape (CM725). (6). Remove sealant between pitch housing
and striker strip. use care not to scratch
2. Pitch Control Bearing Housing Assembly, pitch housing. Remove striker strip
Spacer or Striker Strip Replacement from pitch housing.
(Ref. Figure 801)
(7). Cut old striker strip to facilitate
removal from retention strap assembly.
Consumable Materials Do not scratch strap assembly.
Item Nomenclature (8). Clean old sealant from pitch housing
CM222 1,1,1Trichloroethane using 1,1,1, trichloroethane (CM222).
CM425 Sealing compound (9). Cut out area of new striker strip.
Deburr, smooth and radius cut edges.
(1). Support blade and pitch housing from (10). Apply sealant (CM425) to faying
beneath. Remove nuts. washers, and surfaces of the striker strip and pitch
bolts that secure bearing housing. housing.
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622060 Revision 20
MAINTENANCE MANUAL
2.50 INCH
(6.35 CM)
CAUTION:
DO NOT SCRATCH STRAP PACK WHEN INSTALLING
THROUGH STRAP ASSY.
NOTE:
CUT OUT 0.250.50 IN. (6.3512.70 MM) PIECE OF THE 0.250.50 IN.
STRIKER STRIP BETWEEN LOWER BOLT HOLES. (6.3512.70 MM)
DEBURR AND RADIUS-CUT EDGES. (NOTE) G622009A
Figure 801. Striker Strip Replacement
(11). Position pitch control bearing housing 3. LeadLag Link Blade Stop Replacement
on pivot pin (Ref. Figure 802).
Replace blade stop if it is broken, cracked, has bro-
ken spring, or if there are visible bond line cracks
If droop shim washers were re- (Ref. Figure 802).
CAUTION moved from between spacer and
striker strip, same exact thickness removed Consumable Materials
must be reinstalled. There must be an equal (Ref. Section 910000)
number of washers on each of all three bolts. Item Nomenclature
These washers establish correct static droop
between pitch housing and hub. CM206 Chemical coating
(12). Slide spacer into position between CM228 Surface cleaner
bearing housing assembly and striker CM411 Adhesive, epoxy
strip on pitch housing. Install exact
thickness of droop shim washers CM802 Abrasive cloth, aluminum oxide
removed at time of disassembly. Align CM803 Crocus cloth
holes for all three bolts.
Leadlag link assembly must

(13). Install bolts, washers and nuts; torque CAUTION not be removed from pitch con-
Nm) and install safety wire. trol housing for this repair, since retention
bolt cannot be retorqued without special
adapter.
(14). Seal all parting lines (joints) of the
assembly with bead of sealing com- (1). Provide a backup support for link
pound (CM425). assembly. Use 1/2 inch (12.7 mm) wood
dowel and hammer to drive stop from
(15). Perform droop angle check (Ref. Main link. Strike dowel sharply to break
Rotor Hub Droop Angle Adjustment). adhesive bond.
Page 802
Revision 20 622060
MAINTENANCE MANUAL
LEADLAG
BOLT
LEADLAG LINKS
MAIN ROTOR
STRAP PACK
STRIKER STRIP
PITCH CONTROL BEARING

HOUSING ASSEMBLY
PITCH PIVOT PIN

SLEEVE (NOTE 3)
BUSHING SPECIAL WASHER
(NOTE 4)
DROOP SHIM WASHERS
(CAUTION)
HUB
SPACE NUT RETAINING

R BRACKET
PITCH
BEARING (NOTE 5)
STRIKER NUT
COUNTERSUNK
PLATE HEAD SCREW
NOTE 2
PITCH BEARING HOUSING AND

NOTE 1 SPACER INSTALLATION
0.4328 IN.
LEADLAG (1.03872 MM)
STOP DIA. MIN.
LEADLAG LINK AND STOP
CAUTION:
WASHERS ARE INSTALLED BETWEEN SPACERS AND STRIKER STRIP TO ESTABLISH
CORRECT STATIC DROOP ANGLE BETWEEN HOUSING AND HUB. EXACT NUMBER
REMOVED MUST BE REINSTALLED. THREE PITCH BEARING HOUSING BOLTS MUST EACH
HAVE SAME NUMBER (THICKNESS) OF WASHERS WHEN SHIMMING IS NECESSARY.
NOTES:
1. FOR REMOVAL, WOOD DOWEL PLACED HERE AND STRUCK SHARPLY WITH
HAMMER TO BREAK STOP BOND.
2. ALL STOPTOLINK SHADED CONTACT SURFACES BONDED WITH ADHESIVE.
3. THREADED SHANK LIGHTLY LUBRICATED WITH GREASE BEFORE INSTALLATION.
4. WET PRIMER ON WASHER AND MATING SURFACES BEFORE INSTALLATION.
5. NUT RETAINING BRACKET IS BONDED TO HUB.
6G62029A
Figure 802. Main Rotor Hub Components Repair and Installation
Page 803
622060 Revision 20
MAINTENANCE MANUAL
(2). Using sharpedge metal scraper, Do not disturb torque on lead

carefully scrape any adhesive residue CAUTION lag bolts. Special adapter is
from link. If scraper penetrates through needed to retorque leadlag bolts.
paint and chemical surface film, surface
must be refinished. Depth of gouges or (1). Remove and tag or colorcode each set
nicks is limited to 0.010 inch (0.254 of balance hardware that is installed.
mm) maximum after rework. Rework (2). Remove corrosion with grade 180
by smooth blending into surrounding abrasive cloth (CM802) and finish with
area with grade 320 abrasive cloth grade 400 abrasive cloth.
(CM802). Final polish with crocus cloth
(CM803). Restore chemical film protec- (3). Swab cleaned surface with MEK
tion (CM206). (CM219) and apply unthinned primer
(CM318).
(3). Clean bond area of all contact surfaces
by wiping with cleaner (CM228). (4). Reinstall original balance hardware
Flushwipe cleaned surface four times that was removed. Using sealant
with mixture of equal parts of distilled (CM425), reseal balance hardware.
water and isopropyl alcohol (CM217) to 5. Pitch Control Bearing Pivot Pin Repair or
remove all traces of phosphoric acid. Replacement
Rinse cleaned surface with tap water,
followed by a rinse of distilled water (Ref. Figure 802) Minimum allowable pin diame-
ter is 0.4328 inch (10.993 mm). Pivot pin grooving
until surface is water break free. Dry
or excessive side wear may be polished to original
for 30 minutes minimum at 150F
finish as long as minimum allowable pin diameter
(66C). remains after rework. Replace any pin requiring
(4). Check fit of stop in link. Flange and more rework as follows.
radius contact surfaces of stop must
mate with link within 0.010 inch (0.254 Consumable Materials
mm). Maximum clearance between stop (Ref. Section 910000)
and inside surfaces of link ears is Item Nomenclature
limited to 0.020 inch (0.508 mm). This CM115 Grease, oscillating bearing
tolerance applies to both sides of stop. CM420 Sealant
(5). Prepare mixture of epoxy adhesive

(CM411). Apply uniform coating of (1). Remove pivot pin.
mixed adhesive to all contact surfaces.
(2). Lightly lubricate shank of replacement
Hand press stop into place between link
pivot pin with grease (CM115).
ears until all mating surfaces are in
firm contact. Apply a clamping device NOTE: Torque pivot pin to 70 80 inch
so that contact is maintained. Cure for pounds (7.91 9.04 Nm), then use 0.002
minimum of eight hours at room inch (0.0508 mm) feeler gage and check for
temperature, or two hours at 150F gap between pin flange and washer on
(66C). mounting lug surface. No gap is allowed.
4. LeadLag Bolt Corrosion Control (3). Install pivot pin in mounting lug with
washer. Torque pivot pin to 250 280
Consumable Materials Apply sealant (CM420) at junctures of
(Ref. Section 910000) pivot pin flange, washer and hub.
Item Nomenclature
CM219 Methylethylketone 6. Droop Stop Roller Repair or Replacement
CM318 Primer (Ref. Figure 803) Replace defective droop stop roll-
er if clearance between roller bearing liner and
CM425 Sealing compound shaft is more than 0.015 inch (0.381 mm). Roller
CM802 Abrasive cloth, aluminum oxide shaft outside diameter must not be less than
0.4370 inch (11.0998).
Page 804
Revision 20 622060
MAINTENANCE MANUAL
clearance between striker plates and

Consumable Materials droop stop rollers.
Item Nomenclature (2). If necessary, release retaining (snap)
ring of each droop stop restrainer from
its groove. Move retaining ring flush
against droop stop follower (Thead) to
(1). Move pitch control bearing housing out provide additional clearance and reduce
of the way that contacts lower shoe spring tension.
roller to be removed.
(3). Remove six droop stop rollers.
NOTE: It may be easier if only one roller is re-
moved at one time. The opposing pitch hous- (4). Starting from either scissors crank
ing may be pressed against its follower to attach lug, number, or color code, all six
force opposite follower out and expose roller droop stop follower assemblies in
shaft for removal. Same condition exists at clockwise direction for location identifi-
installation. cation at replacement. This number
code should be placed on outer, upper
(2). Remove droop stop roller. end of plunger and on adjacent area of
lower shoe. Ensure codes are not
(3). Wet down and clean plunger and accidentally removed during remaining
mating shoe bushing with isopropyl steps.
alcohol (CM217).
(5). Compress each droop stop follower and
(4). Install roller, shaft and new cotter pin. insert a small wedge from the back side
(5). Install pitch control bearing housing. to hold follower away from droop ring.
7. Droop Stop Ring Repair (6). After all followers are compressed,
remove droop stop ring.
(Ref. Figure 803)
When installing droop stop ring,
Consumable Materials CAUTION droop stop followers THeads
(Ref. Section 910000) must be offset away from lower shoe to pre-
Item Nomenclature vent damage to lower shoe.
CM103 Solid film lubricant
(7). Install replacement droop stop ring by
reversing removal procedure, steps (1).
(1). Repair depth limit for corrosion, nicks thru (6)., making certain to reinstall
or scratches in droop stop ring is 0.007 followers according to markings placed
inch (0.1778 mm) for all surfaces except thereon prior to removal.
outer edges of ring outer flanges where
the depth limit is 0.030 inch (0.762 (8). Compress follower spring and install
mm). All reworked areas must be retaining (snap) ring, if removed, in its
blended smoothly with 15 to 1 ratio into groove on each follower.
surrounding area. (9). Reinstall droop stop rollers, shafts and
(2). Spray repaired areas of rings with solid cotter pins.
film lubricant (CM103).
9. Droop Stop Follower (THead)
(3). Replace droop stop ring if repair limits Replacement
are exceeded. (Ref. Figure 803) Replace the droop stop follower
(Thead) if it is worn, scored or is causing damage
8. Droop Stop Ring Replacement to the droop stop ring. After the droop stop ring
(Ref. Figure 803) has been removed, the droop stop follower assem-
(1). With hub upside down, support hub so blies may be removed from hub.
that pitch housings unload droop stop (1). Remove droop stop follower assembly
followers and provide maximum from hub.
Page 805
622060 Revision 37
MAINTENANCE MANUAL
LOWER SHOE
DROOP STOP
PINS FOLLOWER
(THEAD) (NOTE)
SNAP RING
COTTER PIN SPRING
DROOP STOP
ROLLER
DROOP STOP PLUNGER
SCISSORS CRANK
ATTACH LUG SHAFT
BEARING ROTATIONAL DRAG
1.0 2.0 INLBS
(0.113 0.226 NM) DROOP STOP FOLLOWER INSTALLATION
DROOP STOP
RING 0.007 IN. (0.178 MM) MAX. DEPTH
(15 TO 1 RADIUS) AFTER REWORK
DROOP STOP FOLLOWER

ASSEMBLY (6 PLACES)
LOWER SHOE INVERTED
0.030 IN. (0.762 MM)

MAX. AFTER REWORK
15 TO 1 RADIUS
DROOP STOP RING REPAIR LIMITS
NOTE: DROOP STOP FOLLOWER THEADS TO

BE OFFSET AWAY FROM LOWER SHOE. 6G62028C
Figure 803. Droop Stop Ring Replacement and Repair
Page 806
Revision 37 622060
MAINTENANCE MANUAL
(2). Remove pins that secure follower to (3). Wet down and clean plunger and
plunger. mating shoe bushing with isopropyl
alcohol (CM217).
Droop stop followers THeads
CAUTION must be offset away from lower (4). Install droop stop plunger into lower
shoe to prevent droop stop ring from damag- shoe.
ing lower shoe. (5). Complete droop stop ring installation.
(3). Insert new follower. Thead must be at (6). Install roller, shaft and new cotter pin.
right angle to roller shaft in plunger.
11. Main Rotor Hub Droop Angle Adjustment
(4). Drill two 0.1560.158 inch (3.9624.013 (Ref. Figure 802) If static droop angle exceeds six
mm) diameter holes through follower in degrees, adjust as follows.
line with holes in plunger. (1). Remove main rotor blade.
(5). Insert pins and stake ends. No burrs or (2). Use flat washers of thickness required
roughness permissible after staking. to adjust spacing between spacer and
striker strip. Any one type, or combina-
(6). Install follower assembly in hub. tion, of correct part number washers
(IPC) may be used; however, an identi-
(7). Reinstall droop stop ring. cal washer selection must be installed
on each of three bolts that secure pitch
10. Droop Stop Plunger Removal, Inspection control bearing assembly to pitch
and Installation housing.
(Ref. Figure 803) (3). Remove nuts, washers and bolts, and
separate spacer from striker strip. The
Consumable Materials use of one 0.016 inch (0.406 mm)
(Ref. Section 910000) washer raises static droop angle
Item Nomenclature approximately onehalf degree. Add
sufficient washers to adjust droop angle
within range of 5.5 0.5 degrees.
Reinstall nuts, washers and bolts.
(1). Remove droop stop ring (Ref. Droop (4). If more than 0.063 inch (1.6 mm)
Stop Ring Replacement). spacing is required (above factory
spacing), inspect striker plate and
(2). Check droop stop plunger for wear by droop stop roller or follower and droop
using the following criteria: stop ring for excessive wear. Replace as
required.
NOTE: The minimum acceptable diameter af-
ter wearing in service should be 0.996 inch (5). Reinstall blade. Repeat measurement of
(25.298 mm). The acceptable amount of static droop angle.
wear though the anodized coating shall not (6). As required, repeat above procedures
exceed 40% or 2.1 square inches (28.45 for remaining blades.
square cm) of the total sliding surface area
of the cylinder. The maximum wear condi- (7). Following reinstallation or replacement
tion may exist in one spot or in several spots of parts, check track of main rotor
totaling 2.1 inches (28.45 square cm). blades.
Page 807
622060 Revision 37
MAINTENANCE MANUAL
12. Main Rotor Hub Tapered Bearing Grease (b). Restore chemical film protection
Repack, Inspection and Replacement where removed.
(Ref. Figure 805)
(c). Maximum diameter of hub bore for
upper bearing cup (Ref. Figure 805)
Consumable Materials is 4.4335 inches (11.25 cm), measured
(Ref. Section 910000) in any direction.
Item Nomenclature
CM111 Grease, aircraft (d). Maximum diameter of hub bore for
CM121 Preservation oil lower bearing cup is 4.3095 inches
(10.95 cm), measured in any direc-
tion.
CM803 Crocus cloth (5). Check upper seal retainer:
(a). No cracks, sharp nicks or burrs are
Special Tools
allowed.
Item Nomenclature (b). Minor corrosion or other surface
ST701 Main rotor wrench assembly defects may be polished out using
crocus cloth (CM803).
Do not intermix Timken or NTN (c). Grooving on seal contact surfaces
CAUTION bearing cups and cones at upper must not exceed 0.004 inch (0.10 mm)
and lower tapered roller bearing locations of depth after polishing.
main rotor hub.
Bearing cups are installed in
NOTE: WARNING hub by differential tempera-
D Roller bearing cones and cups should al- ture (shrinkfit) method. Take appro-
ways be replaced as a set. priate precautions to prevent burns
when handling parts that are cooled to
D Replace tapered roller bearing cup and
subzero temperatures.
cone if it has any flat spots, scoring, pit-
ting, grooving, discoloration (blue) or if it (6). Place bearing cups in closed container
feels rough when rotated. of dry ice and cool for not less than 20
(1). Use pressing tools equivalent to items minutes to 40F (40C).
A and B (Ref. Figure 804) to press (7). Coat bores of hub with grease (CM111).
upper and lower bearing cups from hub.
A press ram of one to two tons is (8). Use care to maintain cuptohub bore
sufficient for removal. alignment and press cup into bore,
using tools D and E (Ref. Figure 804),
(2). Press lower bearing cone from sleeve until cup is seated.
bushing.
(9). Apply film of grease (CM111) to sleeve
CAUTION able bearings while cleaning. bushing. Use pressing tool equivalent to
tool C, and press bearing cone onto
Coat bearings lightly with oil (CM121) after
sleeve bushing.
cleaning.
(3). Clean hub bore, sleeve bushing, seal (10). With lip on center seal up, hand press it
retainer and reusable bearings using into hub (Ref. Figure 805).
filtered solvent (CM234) spray. (11). Apply film of grease (CM111) on mast.
(4). Check bearing cup hub bore for scoring: Install preassembled sleeve bearing
and bearing cone on mast. Do not apply
(a). Smooth out any roughness with any additional lubricant to roller
grade 400600 abrasive cloth bearing set. Wipe any excess preserva-
(CM802). tive oil from bearing cone and cup.
Page 808
Revision 37 622060
MAINTENANCE MANUAL
A A
2.875 IN. (7.3025 CM)

CUT OUT AFTER 0.50 IN. OUTSIDE DIAMETER
BEVELING (12.7 MM)
3.50 IN. (8.89 CM)

OUTSIDE DIAMETER
3.875 IN.
(9.8425 CM) 11.0 IN.
53 (27.94 CM)

5.75 IN.
3.375 IN. (14.605 CM)
0.375 IN. (8.5725 CM)
(9.525 MM)
0.1875 IN. (4.7625 MM) 0.203125 IN. (5.159375 MM)

4130 STEEL PLATE WALL STEEL PIPE WALL STEEL PIPE
A B C
4.40 IN. 4.30 IN.

(11.176 CM) (10.922 CM)
2.58 IN. 0.30 IN.
(6.5532 CM) (7.62 MM)
3.50 IN.
(8.89 CM)
2.0 IN. 2.0 IN.
(5.08 CM) (5.08 CM)
ALUMINUM ALLOY ALUMINUM ALLOY STEEL RING WASHER
D E F
TOOL USE:
A & B PRESS BEARING CUPS OUT OF HUB

C PRESS LOWER BEARING CONE ON SLEEVE BUSHING
D PRESS UPPER BEARING CUP INTO HUB
E PRESS LOWER BEARING CUP ONTO HUB
F IN PLACE OF UPPER SEAL RETAINER WHILE ADJUSTING ROTATIONAL DRAG
G HUB BEARING REMOVAL FABRICATION
G6220101
Page 809
622060 Revision 22
MAINTENANCE MANUAL
7.0 INCH (17.78 CM)

SQUARED
4.75 INCH
(12.065 CM)
10.0 INCH (25.40 CM)

0.75 INCH SQUARED
MATERIAL: WOOD (19.05 MM) H6220102A

If hub assembly does not seat NOTE: When determining spacer thickness,
CAUTION properly onto mast, do not at- start with thick spacer and work down to
tempt to force it into position. Remove hub thinner spacer.
assembly from mast and determine cause of
hub not seating, correct the problem and fol- (a). Install subsequently thinner spacers,
low the procedures for reinstallation. from kit K600N1200A, starting
with a thick spacer, along with cone,
(12). Place assembled hub over mast and substitute washer for retainer and
seat on lower roller bearing cone. locknut.
(13). Install upper bearing cone into hub.
(b). Torque nut to to 200 250 foot
NOTE: Use of substitute steel ring washer for pounds (271 339 Nm) until 10
retainer prevents unnecessary scoring of re- 15 inchpounds (1.13 1.69 Nm)
tainer. Several tightening and loosening ac- of rotational drag (not break
tions may be required to get rotational drag away torque) is obtained on hub.
on hub bearings.
(18). When proper torque has been reached,
(14). Install steel ring washer, equivalent to disassemble and remove steel ring
tool F (Ref. Figure 804), as substitute washer.
for seal retainer (Ref. Figure 805)
(19). Alternative method for determining
(15). Install mast nut on mast using mast thickness required for spacer:
nut wrench (ST701), tighten until
bearings are preloaded to 10 12 (a). Install 369A12245 lead spacer in
inchpounds (1.13 1.36 Nm) of place of the 369A12243 spacer.
rotational drag. Measure rotational
drag using 0 10 pound (0 4.536 kg) (b). Place steel ring washer for retainer
spring scale hooked over one of hub and locknut on the mast and gradual-
support web bosses, 6.5 inch (16.51 cm) ly tighten the retaining nut until
from hub centerline). A 1.50 1.75 rolling torque of 10 15 inch
pound (0.681 0.795 kg) pull with pounds (1.13 1.69 Nm) of rota-
hub in motion indicates correct rotational drag (not breakaway
tional drag. torque) is obtained on hub. If the 10
(16). Remove locknut, washer and cone. 15 inchpounds (1.13 1.69 Nm)
of rotational drag is exceeded,
(17). To determine thickness required for discard the lead washer, install new
spacer: washer and continue.
Page 810
Revision 37 622060
MAINTENANCE MANUAL
(c). When proper torque has been

reached, disassemble and measure Consumable Materials
thickness of the lead washer in the (Ref. Section 910000)
bearing seat area. Grind the Item Nomenclature
369A12243 spacer to the same CM111 Grease, aircraft
thickness as measured on the lead CM204 Compound, corrosion preventative
washer. Check thickness of ground CM121 Preservation oil
washer at six locations to ensure
thickness does not vary by more than
0.0005 inch (0.0127 mm). CM702 Lockwire CRES
(d). Reassemble with the ground steel Special Tools

washer, steel ring washer and (Ref. Section 910000)
locknut and torque to 200 250 Item Nomenclature
footpounds (271 339 Nm) until ST701 Main rotor wrench assembly
10 15 inchpounds (1.13 1.69 ST703 Main rotor hub driver
Nm) of rotational drag (not
breakaway torque) is obtained on
hub. (1). Remove main rotor hub assembly (Ref.
Main Rotor Hub Removal) and place on
bench.
(20). Remove hub and sleeve bushing with
lower bearing cone from mast. (2). Remove upper bearing cone.
Do not intermix Timken or NTN
CAUTION bearing cups and cones at upper
(21). Position hub upsidedown. Handpack and lower tapered roller bearing locations of
lower hub cavity (Ref. Figure 805) and main rotor hub.
bearing cone on sleeve bushing with
grease (CM111). NOTE:
D Roller bearing cones and cups should al-
ways be replaced as a set.
(22). Install sleeve bushing with bearing D Replace tapered roller bearing cup and
cone in hub. Handpack cavity between cone if it has any flat spots, scoring, pit-
bearing and hub liner with grease ting, grooving, discoloration (blue) or if it
(CM111); then press in lower seal with feels rough when rotated.
seal lip toward top of hub. Wipe off
excess grease. (3). Use pressing tools equivalent to items
A and B (Ref. Figure 804) to press
upper bearing cup from hub. A press
(23). Turn hub assembly right side up. ram of one to two tons is sufficient for
removal.
(24). Complete reassembly of hub by install- CAUTION able bearing while cleaning.
ing recessed spacer, upper bearing cone,
upper seal and seal retainer in hub at Coat bearings lightly with oil (CM121) after
installation of hub on mast. cleaning.
(4). Clean hub bore, sleeve bushing, seal
retainer and reusable bearing using
13. Main Rotor Hub Upper Bearing Grease filtered solvent (CM234) spray.
Repack, Inspection and Replacement (5). Check bearing cup hub bore for scoring:
The following procedure is for greasing, inspection (a). Smooth out any roughness with
and replacement of the main rotor hub upper grade 400600 abrasive cloth
bearing only. (CM802).
Page 811
622060 Revision 22
MAINTENANCE MANUAL
(b). Restore chemical film protection (13). Handpack hub cavity, between sleeve
where removed. bushing and hub, with grease (CM111).
(c). Maximum diameter of hub bore for (14). Apply film of grease (CM111) on upper
upper bearing cup (Ref. Figure 805) bearing cone and place into hub.
is 4.4335 inches (11.25 cm), measured
in any direction. NOTE: Use of substitute steel ring washer for
retainer prevents unnecessary scoring of re-
(6). Check upper seal retainer. tainer. Several tightening and loosening ac-
tions may be required to get rotational drag
(a). No cracks, sharp nicks or burrs are
on hub bearings.
allowed.
(b). Minor corrosion or other surface (15). Install steel ring washer, equivalent to
defects may be polished out using tool F (Ref. Figure 804), as substitute
crocus cloth (CM803). for seal retainer (Ref. Figure 805)
(c). Grooving on seal contact surfaces (16). Install mast nut on mast using mast
must not exceed 0.004 inch (0.10 mm) nut wrench (ST701), tighten until
depth after polishing. bearings are preloaded to 10 12
inchpounds (1.13 1.36 Nm) of
Bearing cups are installed in rotational drag. Measure rotational
WARNING hub by differential tempera- drag using 0 10 pound (0 4.536 kg)
ture (shrinkfit) method. Take appro- spring scale hooked over one of hub
priate precautions to prevent burns support web bosses, 6.5 inch (16.51 cm)
when handling parts that are cooled to from hub centerline). A 1.50 1.75
subzero temperatures. pound (0.681 0.795 kg) pull with
hub in motion indicates correct rota-
(7). Place bearing cup in closed container of tional drag.
dry ice and cool for not less than 20
minutes to 40F (40C). (17). Remove locknut, washer and cone.
(8). Coat bore of hub with grease (CM111). (18). To determine thickness required for
spacer:
(9). Use care to maintain cuptohub bore
alignment and press cup into bore, NOTE: When determining spacer thickness,
using tools D and E (Ref. Figure 804), start with thick spacer and work down to
until cup is seated. thinner spacer.
If hub assembly does not seat
CAUTION properly onto mast, do not at-
(a). Install subsequently thinner spacers,
from kit K600N1200A, starting
tempt to force it into position. Remove hub with a thick spacer, along with cone,
assembly from mast and determine cause of steel ring washer for retainer and
hub not seating, correct the problem and fol- locknut.
low the procedures for reinstallation.
(b). Torque nut to to 200 250 foot
pounds (271 339 Nm) until 10
main rotor hub and position over mast;
then lower hub onto mast.
of rotational drag (not break
NOTE: To inhibit mast corrosion when operat- away torque) is obtained on hub.
ing in salt water environment, lightly coat
bearing journals of mast with grease (19). When proper torque has been reached,
(CM111). disassemble and remove steel ring
washer.
(20). Alternative method for determining
(12). Check that hub is fully seated on mast. thickness required for spacer:
Page 812
Revision 34 622060
MAINTENANCE MANUAL
(a). Install 369A12245 lead spacer in (1). Remove main rotor hub (Ref. Main
place of the 369A12243 spacer. Rotor Hub Replacement).
(b). Place steel ring washer for retainer (2). Invert hub and place on work bench.
and locknut on the mast and gradual-
ly tighten the retaining nut until (3). Remove droop stop ring (Ref. Droop
rolling torque of 10 15 inch Stop Ring Replacement).
pounds (1.13 1.69 Nm) of rota-
tional drag (not breakaway (4). Press bearing from hub lug.
torque) is obtained on hub. If the 10
15 inchpounds (1.13 1.69 Nm) (5). Clean bearing bore with locktite
of rotational drag is exceeded, remover (CM216).
discard the lead washer, install new
washer and continue. (6). Inspect bearing bore for nicks,
scratches and grooves.
(c). When proper torque has been
reached, disassemble and measure (7). Inspect bore for diameter of
thickness of the lead washer in the 0.65510.6556 inch (16.6395416.65224
bearing seat area. Grind the mm).
369A12243 spacer to the same
thickness as measured on the lead (8). Touch up bearing bore with chemical
washer. Check thickness of ground coating (CM206).
washer at six locations to ensure
thickness does not vary by more than (9). Apply surface primer (CM321) to
0.0005 inch (0.0127 mm). mating surfaces of bearing and boreas
per manufacturers instructions.
(d). Reassemble with the ground steel
washer, steel ring washer and NOTE: Do not allow primer to enter bearing.
locknut and torque to 200 250
footpounds (271 339 Nm) until (10). Apply locking compound (CM431) to
10 15 inchpounds (1.13 1.69 faying surfaces of bearing and bore,
Nm) of rotational drag (not press bearing into bore while locking
breakaway torque) is obtained on compound is wet.
hub.
(11). Remove excess sealant, do not allow
(21). Complete reinstallation of main rotor sealant to enter bearing.
hub assembly (Ref. Main Rotor Hub
Installation). (12). Apply a small fillet of sealant around
bearing and allow to dry for 24 hours at
room temperature or heat to 140
14. Main Rotor Hub Scissors Attach Lug 160F (60 72C) for one hour.
Bearing Replacement
(13). As required, touch up bearing lug with
Consumable Materials paint (CM304).
Item Nomenclature (14). Check bearing for a noload rotational
drag of 1.0 2.0 inchpounds (0.113
CM206 Chemical coating 0.226 Nm).
CM216 Loctite remover
CM304 Enamel, epoxy (15). Reinstall droop stop ring (Ref. Droop
Stop Ring Replacement).
CM321 Surface primer locking compound
CM431 Sealing, locking and retaining compound (16). Reinstall main rotor hub (Ref. Main
Rotor Hub Replacement).
Page 813
622060 Revision 34
MAINTENANCE MANUAL
SEAL DROOP SHIM WASHER

(NOTE 4) (NOTE 6)
SEAL RETAINER HUB STRIKER
STRIP PITCH
PIVOT PIN SEALANT
UPPER BEARING CONE (NOTE 2) HOUSING
(NOTE 7)
NOTE 1
UPPER BEARING CUP
(NOTE 7)
(NOTE 5)
SEAL PITCH
(NOTE 4) BEARING
SLEEVE
RECESSED BUSHING
SPACER
(NOTE 3) SEALANT STRAP
(NOTE 2) PACKS
LOWER SHOE
NOTE 5
DROOP STOP RING STRAP

NOTE 8 ASSEMBLY
SPRING NOTE 1
HUB OUTER LINER ROLLER SPACER
SEAL LOWER BEARING CONE RETAINING ASSEMBLY
(NOTE 4) (NOTE 7) CLIP FOLLOWER PITCH CONTROL
ASSEMBLY BEARING HOUSING
LOWER BEARING CUP
(NOTE 7)
BUSHING LEADLAG PIVOT BOLT
PITCH HOUSING SEALANT

BEARING (NOTE 2)
(NOTE 1)
LEADLAG
LINKS
SHIM
STRAP ASSEMBLY BUSHING

COTTER PIN
NUT
NOTES:
1. HEAVY LINES INDICATE REINFORCED TEFLON BEARING LININGS (TYPICAL).
2. SEALANT APPLIED TO LOCATIONS SHOWN.
3. RECESSED SPACER SPECIALLY GROUND TO ESTABLISH CORRECT ROTATIONAL
DRAG ON TAPERED BEARINGS. INSTALL RECESS DOWN ON TOP OF SLEEVE BUSHING.
4. SEAL TO BE UPWARD.
5. BEARING AND CAVITY TO BE FILLED WITH GREASE.
6. DROOP SHIM WASHERS ARE INSTALLED, AS REQUIRED, TO OBTAIN PROPER
ROTOR DROOP ANGLE.
7. DO NOT INTERMIX TIMKEN AND NTN BEARING CUPS AND CONES AT UPPER AND
LOWER TAPERED BEARING LOCATIONS.
8. DROOP STOP FOLLOWER THEAD TO BE OFFSET AWAY FROM LOWER SHOE.
6G62030A
Figure 805. Main Rotor Hub Cross Section
Page 814
Revision 37 622060
MAINTENANCE MANUAL
Section
623000
Swashplate and
Mixer (369D/E/FF
500N)
MAINTENANCE MANUAL
SWASHPLATE AND MIXER

1. Main Rotor Swashplate B. Swashplate Installation
(Ref. Figure 403) The main rotor swashplate (1). If swashplate lower boot was removed,
includes a rotating swashplate, stationary install boot on mast (Ref. Figure 403).
swashplate, bearing and retainer and two
counterweights. (2). Position swashplate over main rotor
mast and carefully lower into place.
2. Swashplate Replacement (3). Engage upper end of boot in groove at
A. Swashplate Removal lower side of stationary swashplate.
Secure boot with selfclinching nylon
(1). Tag or coloridentify five pitch control strap (Ref. Figure 403).
rods (Ref. Figure 401) to simplify
(4). Align longitudinal link with stationary
replacement at same locations.
swashplate (Ref. Figure 402).
Failure to reinstall pitch control
CAUTION rods at correct locations prob-
(5). Install flanged bushing, if removed,
bolt, two washers, nut and cotter pin to
ably will result in main rotor blades exces-
secure upper end of longitudinal link.
sively out of track.
(6). Align upper ends of mixer links with
(2). Disconnect pitch control rods from stationary swashplate. Install slotted
rotating swashplate. bushing (if removed), bolt, two washers,
(3). Remove scissors. nut and cotter pin to secure each link to
swashplate.
(4). Remove main rotor hub.
(7). Install scissors.
(5). Disconnect longitudinal link (Ref. (8). Using color code, reinstall pitch control
Figure 402) from stationary swash- rods at same locations from which
plate. removed.
(6). Disconnect right and left side mixer (9). Check track of main rotor blades (Ref.
links (Ref. Figure 402) from stationary Chap. 18) following any maintenance
swashplate. activity that could result in a dimen-
(7). Remove protective boot from groove in sional variation affecting rigging or
lower side of stationary swashplate tracking.
(Ref. Figure 403).
3. Mixer Controls
Do not strike rotating swash-
CAUTION plate or bearing assembly (Ref.
Mixer controls consist of various links,
bellcranks, idlers, support bracket and
Figure 403) with tools or in any way deface associated fasteners that secure these compo-
these components. Rotating swashplate is a nents in place and to the control rods and main
stressed part; all surfaces are shot peened. rotor swashplate.
Use particular care to protect teflon liner in
bearing bore. A damaged swashplate bear- 4. Mixer Controls Replacement
ing must not be retained in service.
A. Mixer Controls Removal
(8). Lift swashplate carefully up and off of
mast. (Ref. Figure 402)
(9). To remove boot from mast, remove (1). Remove air intake forward fairing for
selfclinching nylon strap. access.
Page 401
623000 Revision 20
MAINTENANCE MANUAL
ROTOR HUB CLOSE TOLERANCE 6.25 IN.

LOWER SHOE BOLT (15.875 CM)
WASHERS SCISSORS CRANK PITCH CONTROL ROD LENGTH

(NOTE 4) (NOTE 3)
SLOTTED BUSHING
(NOTE 1) MAXIMUM ALLOWABLE LOOSENESS
0.040 IN. (1.016 MM)
AT INSTALLATION, ROD
ENDS TO BE PARALLEL
WITH MATING CLEVIS
BEARING 1.30 IN. (3.302 CM) TYPICAL

(UPPER BEARING ONLY)
WASHERS
(NOTE 4)
BUSHING
SCISSORS LINK
BEARING PITCH CONTROL ROD

(NOTE 2)
ELASTOMER RING
SLOTTED BUSHING (NOTE 6)
(NOTE 1)
ELASTOMER RING
(NOTE 5)
ROTATING
SWASHPLATE
INTERRUPTER
SLOTTED BUSHING
COLLECTIVE PITCH (NOTE 1)
CONTROL ROD
LONGITUDINAL PITCH
CONTROL ROD
SLOTTED BUSHING
(NOTE 1)
NOTES:
LATERAL PITCH 1. END OF SLOTTED BUSHING MUST PROTRUDE MINIMUM OF
CONTROL ROD 0.010 IN. (0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. COLOR CODED TO MATCH BLADE.
3. OPTIMUM INITIAL SETTING (FIVE PLACES).
4. AS REQUIRED TO FILL GAP.
5. THIS SIDE ONLY ON EARLY CONFIGURATION.
6. BOTH SIDES ON CURRENT CONFIGURATION.
7. DELETED
G623000D
Figure 401. Pitch Control Rods and Swashplate Scissors Installation
Page 402
Revision 36 623000
MAINTENANCE MANUAL
(2). Disconnect upper ends of collective support bracket and bore in mast base
mixer, lateral mixer and longitudinal lug is 0.015 inch (0.381 mm) or less.
mixer control rods (Ref. Figure 401).
NOTE: If necessary, loosen aft two bracketto
NOTE: Control rods are attached by slightly fitting nuts, position support bracket to
different length bolts. Reinstall each bolt in minimize misalignment and retighten nuts.
its bellcrank following control rod removal
to simplify reinstallation at correct loca- (4). Install mixer support attaching bushing
tions. in bracket and mast base lug.
(3). Remove mixer links. (Mixer link (5). Check that sleeve bushing is in place;
bearings are not replaceable.) then install bolt, two washers and nut.
Torque nut to 80 100 inchpounds
(4). Disconnect longitudinal link from (9.04 11.30 Nm).
stationary swashplate.
(6). Position longitudinal pitch idler and
(5). Remove longitudinal control mixer link. collective pitch mixer bellcrank on
support bracket. Position washer
(6). Disconnect lateral bellcrank from between right side of longitudinal pitch
collective pitch mixer bellcrank. idler bearing and center bearing of
mixer support bracket. Install left
(7). Remove connecting hardware (includ- hand bearing, with attaching hardware.
ing flanged bushing) from each side of
longitudinal pitch mixer bellcrank. (7). Position lateral bellcrank between
Carefully remove bellcrank. Retain any collective pitch mixer bellcrank bear-
shims that may be installed. ings and install attaching hardware.
(8). Remove bolt from hingeline of support (8). Position longitudinal pitch mixer
bracket, longitudinal pitch idler and bellcrank with collective pitch mixer
collective pitch mixer bellcrank. bellcrank; insert two flanged bushings.
Separate the three parts. Install two bolts.
(9). Remove mixer support bracket from (9). Push longitudinal bellcrank to one side
mast base. and measure gap between bellcrank
and bearings in collective pitch bell-
To prevent washing dirt into crank.
CAUTION bearings, or washing grease out
of bearings, do not permit solvent to enter (10). Using HS50792646 laminated wash-
bearings when cleaning mixer control com- er(s), shim evenly to take up gap.
ponents.
(11). Insert flanged bushings, bolts, six
B. Mixer Controls Installation washers (two under each nut) shims
and nuts. Torque nut to 30 40 inch
(Ref. Figure 402) pounds (3.39 4.52 Nm) and install
cotter pin.
(1). Position support bracket over forward
lug on mast base. (12). Position longitudinal control mixer link
between longitudinal pitch idler and
(2). Install two aft bolts and washers in longitudinal pitch mixer bellcrank;
support bracket and mast base. Install check that two slotted bushings are in
two thin washers and nuts; torque nuts place. Install bolt, three washers (two
to 80 100 inchpounds (9.04 11.30 under each nut), nut and cotter pin at
Nm) above drag torque. each end of link.
(3). Using ball hole gage and standard (13). Position longitudinal link between
micrometer, check that misalignment longitudinal pitch mixer bellcrank
between forward bolt hole bore in bearings. Install attaching hardware.
Page 403
623000 Revision 31
MAINTENANCE MANUAL
BUSHING
(NOTE 2) LONGITUDINAL
PITCH IDLER LONGITUDINAL CON-
TROL MIXER LINK
MIXER LINK
STATIONARY
*LATERAL MIXER SWASHPLATE BUSHING
BELLCRANK (NOTE 2)
BEARING BUSHING
(NOTE 2)
WASHER MIXER FLANGED

LINK STATIONARY BUSHING
MIXER SUP- SWASHPLATE BEARING
PORT ATTACH-
ING BUSHING
(NOTE 6) BEARING
BUSHING
MIXER NOTE 1
FLANGED (NOTE 2)
SUPPORT
BUSHING LONGITUDINAL
BRACKET
(NOTE 4) LINK (NOTE 3)
BEARING NOTE 1
*COLLECTIVE
PITCH MIXER
BEARING BELLCRANK
BEARING
SLEEVE NOTE 7
BEARING
BUSHING
FLANGED *LONGITUDINAL
BUSHING PITCH MIXER
NOTE 1 (NOTE 4) BELLCRANK
2 PLS
MAST
BASE
NOTES:
1. DIRECTION OF BOLT OPTIONAL.
2. EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN. (0.254 MM) TO MAXIMUM OF
0.060 IN. (1.524 MM) ABOVE OUTSIDE OF PART AFTER NUT IS TIGHTENED.
3. LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY.
4. MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.
5. ASTERISK ( * ) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.
(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL, REF. SEC. 204000).
6. INSTALL BUSHING AFTER THE TWO AFT ATTACHING BOLTS WITHOUT EXCESSIVE
MISALIGNMENT, 0.015 IN. (0.381 MM).
7. USING HS50792646 SHIMS, SHIM EQUALLY TO REMOVE GAP.
G623003C
Figure 402. Mixer Controls Assembly
Page 404
Revision 31 623000
MAINTENANCE MANUAL
(14). Position mixer links in stationary Scissors crank must be posi-

swashplate and lateral bellcrank; check CAUTION tioned (Ref. Figure 401) with de-
that slotted bushings are in place. cal up and proper direction towards lower
Install attaching hardware. side lugs.
(15). Place collective mixer, lateral mixer NOTE: Ensure cranktohub lower shoe lugs
longitudinal mixer control rods (Ref. are not preloaded.
Figure 401) in mounting position; check
that slotted bushing in place. Install (3). Position scissors crank on hub lower
attaching hardware. shoe lugs; install connecting hardware
(Ref. Figure 401). Torque nuts to 30
(16). Install air intake forward fairing. 60 inchpounds (3.39 6.78 Nm);
install cotter pin.
(17). Check rigging of collective and cyclic
controls. NOTE: Shim washers may be required on
shouldered bushing side of clevis.
5. Scissors
(4). Position elastomer rings and lower end
The scissors provide a movable connection of pitch control rod in swashplate lug
between the rotating swashplate and main and install attaching hardware. (Nut is
rotor hub. to be adjacent to bushing in swash-
plate.) Torque nut to 30 60 inch
6. Scissors Replacement pounds (3.39 6.78 Nm).
A. Scissors Removal 7. Scissors Link Replacement
(Ref. Figure 401)
Removal of all pitch control rods (Ref. Section 910000)
CAUTION is recommended prior to scissors
Item Nomenclature
removal. Failure to observe this precaution
could result in damage to pitch control rods, CM103 Solid film lubricant
swashplate and/or hub.
(1). Disconnect lower end of pitch control (1). Remove cotter pin, nut, washer and bolt
rod that is in line with scissors link in that join link and crank.
rotating swashplate. (2). Remove two bushings from link only if
(2). Remove cotter pin, nut, washer, and replacement is necessary.
bolt from each leg of scissors crank.
(3). Do not remove bearing from link,
Disconnect crank from hub lower shoe.
replace complete link if bearing is
(3). Remove cotter pin, nut, washer, and defective.
bolt connecting scissors link to swash-
plate; remove scissors.
NOTE: Install new bushings using solid film lu-
bricant (CM103); do not use zinc chro-
B. Scissors Installation mate.
(Ref. Figure 401) (4). If bushings were removed at disassem-

bly, install new bushings. After installa-
(1). Place scissors link in mounting position, dimension between outer faces of
tion, chamfered edge of link must face bushings should be 1.5791.586 inches
outboard. (4.01074.0284 cm).
(2). Check that slotted bushing is in (5). Align bore of link with bore of crank;
swashplate web and install attaching install bolt, washer and nut. Torque nut
hardware. Torque nut to 15 20 to 30 40 inchpounds (3.39 4.52
inchpounds (1.69 2.26 Nm). Nm), install cotter pin.
Page 405
623000 Revision 36
MAINTENANCE MANUAL
8. Pitch Control Rods NOTE: Bushing must project 0.0100.060 inch

(0.2541.524 mm) after nut is torqued.
Five pitch control rods transfer pitch control
from the rotating swashplate to the main rotor (4). Torque lower nut to 30 60 inch
blades. pounds (3.39 6.78 Nm).
(5). Secure nuts with cotter pins.
9. Pitch Control Rod Replacement
(6). Rotate pitch change rod assembly fore
A. Pitch Control Rod Removal and aft to ensure clearance exists
between rod end bearing and pitch
(Ref. Figure 401) housing clevis at both ends.
NOTE: (7). If installation is final and tracking is
D If rod is not to be reinstalled, but is to be not required, safetywire rod ends to rod;
replaced, measure and record length of ensure rod ends are centered.
removed rod. Optimum length may have (8). As necessary, repeat above procedures
been changed at previous rigging; pread- for remaining pitch control rods.
just replacement rod to length of rod re-
moved. 10. Counterweight and Interrupter Installation
D Rods are color coded for reinstallation at
correct locations. If more than one rod is Consumable Materials
being removed and color coding is not vis- (Ref. Section 910000)
ible, identify each by color or similar Item Nomenclature
means to points of connection to simplify CM111 Grease, aircraft
reinstallation. CM409 Adhesive, epoxy
(1). Remove cotter pin, nut, washer and bolt
from each end of pitch control rod. NOTE: If counterweights are to be added, one
thick and one thin (any position) is recom-
(2). Remove pitch control rod and Oring. mended for ease of balancing; Hub must be
rebalanced.
B. Pitch Control Rod Installation
(1). Apply coat of adhesive (CM409) to
(Ref. Figure 401) counterweight OD. Reinstall weight
with smaller hole outboard, using
At installation, install rod at
CAUTION correct color code location. Cen-
dummy bolt to align weight to rotating
swashplate. Remove bolt and allow
ter bearing rodends between attach clevis. If adhesive to cure according to container
rod length is changed, blades must be instructions.
tracked.
NOTE: Ensure interrupters are installed with
(1). If actual rod length is incorrect or same type and number of washers removed
either actual or required rod length is at disassembly, and that correct part num-
unknown, preset rod length to optimum ber interrupter is installed in each swash-
length of 6.25 inches (15.875 cm). plate arm. (Ref. CSPIPC4 for correct part
numbers and corresponding locations).
NOTE: Install both pitch change rod bolts in
direction of rotation. (2). Install interrupters, beveled edges
inboard, with bolts, washers, nuts and
(2). Install rod with elastomeric rings on new cotter pins. Coat bolts with grease
both sides of lower bearing. (CM111) prior to installation. Torque
NOTE: Add washers as required to align nut 6.79 Nm).
with cotter pin hole.
(3). Install interrupters using bolts,
(3). Torque upper nut to 100 130 inch washers and nuts; torque nuts to 15
pounds (11.30 14.69 Nm). 20 inchpounds (1.69 2.26 Nm).
Page 406
Revision 27 623000
MAINTENANCE MANUAL
COUNTERWEIGHT
NOTE 2
BEARING AS-
SEMBLY
INTERRUPTER DOUBLE IN-
TERRUPTER
COUNTERWEIGHT
ROTATING
SWASHPLATE
NOTE 2
INTERRUPTER
SPACER INTERRUPTER
INTERRUPTER
STATIONARY
SWASHPLATE
DRAIN HOLES
(HIDDEN)
INDEX PROTRU-
SIONS
STATIONARY
SWASHPLATE DRAIN HOLES
GROOVE (2 PLACES)
BOOT
NYLON STRAP NOTES:

1. COLOR CODED TO MATCH BLADES.
2. IF COUNTERWEIGHTS ARE USED, COAT BOLT WITH
MAST
GREASE (CM116) BEFORE INSTALLATION.
3. DELETED
4. DELETED
BOOT INSTALLATION
G623001A
Figure 403. Main Rotor Swashplate
Page 407
623000 Revision 35
MAINTENANCE MANUAL
Page 408
Revision 35 623000
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Swashplate Inspection (a). Maximum radial play between
sliding surface liner and stationary
mast is 0.020 inch (0.508 mm).
(Ref. Section 910000) (b). Maximum axial play between spheri-
Item Nomenclature cal ball and teflon liner is 0.010 inch
(0.254 mm).
(c). If play is suspected in double row ball
bearing, turn rotating swashplate
When cleaning swashplate for until arms line up with those of
CAUTION inspection, prevent solvent from stationary swashplate and check
entering either spherical ball bearing or motion between arms at control bolt
double row ball bearing. Use cloth moist- in stationary swashplate.
ened in alcohol (CM217) to wipe clean
(d). Maximum total vertical movement of
spherical ball, ball bore liner and exterior of
0.015 inch (0.381 mm) is allowable.
double row ball bearing.
(e). If movement limit is exceeded replace
NOTE: double row ball bearing (Ref. COM).
D Stationary swashplate may be con- (5). Inspect swashplate spherical and
structed of either magnesium or alumi- double row ball bearings for condition.
num alloy. For corrosion control and iden-
tification of magnesium and aluminum (a). Nicks and dents that do not deform
alloys (Ref. Sec. 204000). ID chamfered edge of hard anodized
ball, and not more than 0.10 inch
D In the following inspection, the rotating (0.254 mm) deep along spherical ball
and stationary swashplates must be dis- surface from edge are allowed.
connected (Ref. Swashplate and Mixer
Removal/Installation). (b). Scratches, any length, on OD of
spherical ball are allowed if they are
no deeper than 0.010 inch (0.254
(1). Inspect swashplate bearing assembly
mm) or wider than 0.060 inch (1.524
(Ref. Figure 403 for evidence of binding
mm).
in either radial or axial movement.
(c). Not more than two scratches are
(2). Inspect teflon liners for condition. permitted in a one inch wide area.
(6). Check existing preload on spherical
(3). Ensure that all flexible rubber seals
bearing.
enclosing ball bearing races are in
place; inspect for deterioration and (a). Hook spring scale over one of the
indication of grease leakage. (For bolts securing stationary swashplate
bearing maintenance information to the bearing flange.
(including lubrication), Ref. COM).
(b). With stationary swashplate in
motion, drag should be no more than
NOTE: New swashplate bearing assembly nor-
30 pounds (13.61 kg). (Use average
mally shows some signs of grease leakage
of four readings taken 90 degrees
for first 1015 hours of operation after in-
apart).
stallation.
(c). If readings are more than 30 pounds
(4). Inspect swashplate spherical ball and (13.61 kg), clean spherical bearing
double row ball bearing for radial or with isopropyl alcohol and recheck
axial play. drag.
Page 601
623000 Revision 32
MAINTENANCE MANUAL
(d). Repair damage or replace bearings mixer link for binding, play in link bore
(Ref. COM). and wear. Wear limit is 0.008 inch
(0.203 mm) radially and 0.040 inch
(7). Check double row ball bearing for (1.016 mm) axially. Replace complete
serviceability, with seals in place and mixer link if bearings are faulty.
unbroken. Inspect bearings in other linkage for
(a). Check for correct operation and binding and looseness in mating bores.
lubrication.
3. Scissors Inspection
(b). Bearing must rotate smoothly,
(Ref. Figure 401)
without roughness. Binding or
catching should not exist when Any evidence of failure,
bearings are rotated 360. WARNING damage, or deformation of
(c). Replace defective double row ball crank or link is justification for re-
bearings (Ref. COM). placement of either crank, link, or com-
plete scissors assembly. Failure of any
(8). Perform careful visual inspection of of these components in flight can result
stationary and rotating swashplate for in failure of movable flight controls,
cracks, wear in bolt and bushing bores, loss of helicopter, and possible injury
and fork inner surfaces; and for or loss of life.
corrosion, nicks and dents.
(1). Inspect crank and link for evidence of
(9). Perform dye penetrant check on impact damage and deformation. If
questionable areas. condition is questionable, perform
fluorescent dye penetrant inspection.
(10). Check that counterweights are securely
bonded in rotating swashplate. (2). Inspect bearings for binding, looseness
in bore and wear. Maximum wear limits
2. Mixer Controls Inspection are 0.010 inch (0.254 mm) radial and
0.020 inch (0.508 mm) axial.
(Ref. Figure 402)
(1). Inspect all bushings for security of fit. 4. Pitch Control Rod Inspection
(2). Inspect longitudinal link, support (Ref. Figure 401)

bracket, longitudinal control mixer link, Ensure that rod end bearings
mixer links, longitudinal pitch idler, CAUTION are centered and do not contact
longitudinal pitch mixer bellcrank, attach clevis.
lateral bellcrank and collective pitch
mixer bellcrank for scratches, cracks, (1). Visually inspect upper and lower rod
corrosion and similar surface defects. end bearings for evidence of excessive
For components that are questionable, axial play, 0.040 inch (1.016 mm)
perform fluorescent dye penetrant maximum; and for any extrusion,
inspection. displacement or damage to the bearing
teflon liner.
(3). Inspect spherical, teflon (or equivalent)
lined, bearings in longitudinal link, (2). Replace rod end bearing if discrepan-
mixer link, and longitudinal control cies are noted.
Page 602
Revision 32 623000
MAINTENANCE MANUAL

REPAIRS
1. Swashplate Repairs be restored on magnesium and alumi-
num parts.
(Ref. Figure 403) Disassembly other than as
illustrated is considered a part of swashplate (7). Replace defective bearings and bush-
overhaul (Ref. COM). If tracking interrupters ings, except swaged spherical bearings
are to be removed, mark them for reinstalla- in mixer links which require link
tion at original locations. replacement. Remove bearings or
bushings by pressing them out. Install
2. Mixer Controls Repair new bearing with surface primer and
grade A locking compound (CM321 and
(Ref. Figure 402) CM431).
NOTE: Lefthand bearing in support bracket is
Consumable Materials not supplied as part of bracket. This bearing
(Ref. Section 910000) is installed at time support bracket and lon-
Item Nomenclature gitudinal pitch idler are assembled. Install
CM321 Surface primer locking compound new bearing by seating flush with inner face
CM431 Sealing, locking and retaining compound of support bracket flange.
3. Scissors Bushing and Bearing
Replacement
NOTE: Following depth limits are total limits, (Ref. Figure 401)
including effects of all previous repairs to
any given area.
(1). Repair minor surface defects such as (Ref. Section 910000)
scratches, nicks and corrosion using Item Nomenclature
abrasive cloth, grade 400 600 CM103 Solid film lubricant
(CM802) to smooth out and blend in CM222 1,1,1Trichloroethane
such defects.
CM318 Primer
(2). Cast and forged surfaces may be CM321 Surface primer locking compound
reworked to depth of 0.020 inch (0.508 CM431 Sealing, locking and retaining compound
mm).
(3). Flat machined surfaces, except clevis (1). Remove cotter pin, nut, washer, and
inner ears, may be reworked to depth of bolt that join link and crank.
0.015 inch (0.381 mm). Clevis inner ear
surfaces may be reworked to depth of (2). Remove two bushings from link only if
0.020 inch (0.508 mm). replacement is necessary.
(4). Machined holes may have 0.003 inch (3). Do not remove bearing from link.
(0.076 mm) removed from bore wall in Replace complete link if bearing is
an area no greater than 15 percent of defective.
circumference and 50 percent of depth. (4). Remove slotted bushings and bearings
from crank, only if replacement is
(5). All edges may have 0.030 inch (0.762 necessary.
mm) removed except around machined
holes which are limited to 0.010 inch During cleaning, do not allow
(0.254 mm) chamfer. CAUTION solvent to enter bearings.
(6). All rework must be smoothly blended (5). Install new bushings using solid film
into adjacent surfaces and finish must lubricant (CM103); do not use zinc
Page 801
623000 Revision 20
MAINTENANCE MANUAL
chromate. Press in bushing until end scissors to 369D2100221 configuration to

is flush with inside surface of crank preclude shimming problems experienced with
inboard ears. the early crank configuration. Field rework
consists primarily of relocating existing
(6). If bearings were removed from crank at bushings in the crank outboard attach lugs to
disassembly, reinstall using the the inboard lugs, and installing new flange
following procedure: type bushings in the outboard lugs. The wall
thickness of the crank outboard attach lugs
NOTE: Do not allow sealant to enter bearing must be reduced to accommodate installation
race. of the flange bushings.
(a). Clean bearing outer face, counterbore

and faying surfaces with trichloroe- Instructions are also provided for replacement
thane (CM222). Do not allow trichlo- of existing hardware for the crank assembly.
roethane to enter bearing. Existing attach bolts may have insufficient
thread length which, in some cases, can cause
(b). Coat the faying surfaces with surface loosening of the bolt in service.
primer (CM321) as per manufactur-
ers instructions.
It is to be noted that the field modification and
(c). Apply locking compound (CM431) to installation of the PN 369D2100221 crank
faying surfaces. assembly with new attach hardware also
upgrades the PN 369D21001 scissors assembly
(d). Press bearing until outer face is to PN 369D2101501 configuration.
seated firmly against shoulder of
counterbore.
(e). Remove excess sealant. Do not allow (Ref. Section 910000)
sealant to enter bearing race. Item Nomenclature
(f). Apply a small fillet of sealant to the CM206 Chemical coating

faying edges of bearing housing. Use
CM318 Primer
cellophane or masking tape to
exclude air and allow sealant to cure
for 24 hours at ambient temperature
or force cure by heating to (1). Disconnect scissors crank from hub
140160F (6072C for one hour lower shoe and scissors link.
prior to use of assembly.
(7). If bushings were removed from link at (2). Remove existing HS626S4500
disassembly, install new bushings. bushings from outboard lugs of scissors
After installation, dimension between crank.
outside faces of bushings should be
1.5791.586 inches (4.01074.0284 cm).
(3). Using grinder or file, remove minimum
(8). Align bore of link with bore of crank; 0.063 inch (1.6002 mm) material from
install bolt, washer and nut. Torque nut inner side of both outboard attach lugs,
to 30 40 inchpounds (3.39 4.52 to obtain distance of 9.735 inches
Nm). (24.7295 cm) between lugs. After
removal of material, wall thickness of
4. Scissors Modification lugs should not be less than 0.230 inch
(5.842 mm). Coat reworked area of lug
(Ref. Figure 801) The following procedure is for with iridite (CM206) or equivalent
modification of 369D21002 main rotor hub corrosion protective chemical film.
Page 802
Revision 20 623000
MAINTENANCE MANUAL
9.736 IN.
(24.7295 CM)
NAS77423 BUSHING MINIMUM WALL 0.230 IN. (5.8420 MM) TYP.
NOTE 5 NOTE 5
(TYP. 2 PLCS) HS626S4500 MAXIMUM WALL 0.249 IN. (6.3246 MM) TYP.
BUSHING (2 REQD)
369D2100221 CRANK 0.3750 IN. (9.5250 MM)

0.020 IN. (0.508 MM) X 45
ASSEMBLY 0.3755 IN. (9.5377 MM) DIA.
CHAMFER (4 PLACES)
(NOTE 3)
6.421 IN.
16.3093 CM)
PLATE
NAS620438D BOLT
AN960C416 WASHER
2 REQD (NOTE 2)
MS178264 NUT (NOTE 1)
INSTALL THIS SIDE

TOWARD BLADES
NOTES: NOTE 4
1. TORQUE NUT 30 40 INCHPOUNDS (3.39 4.52 NM).
2. ONE WASHER EACH UNDER BOLT HEAD AND NUT.
SCISSORS LINK
3. TWO HOLES IN LINE (TYP. 2 PLACES) ASSEMBLY
4. FILL GAP WITH HS50792646 WASHERS. SHIM WASHERS
SHOULD BE EQUALLY SPACED.
5. REMOVE MATERIAL EVENLY FROM INNER SIDE OF OUTBOARD
ATTACH LUG TO OBTAIN 9.736 IN. (24.7295 CM) DIMENSION. G623004B
Figure 801. Field Modification 369D2100211 Crank Assembly to 369D2100221 Configuration
NOTE: Remove material only from inner side of (a). Install scissors crank to hub lower
existing crank outboard attach lugs. shoe with NAS620418D bolts,
AN960PD416L washers, MS178264
(4). Using existing hole in outboard lug as nuts and cotter pins (Ref.
guide, drill and ream 0.252 inch (6.4008 Figure 802).
mm) dia. hole in outboard lugs to
0.37500.3755 inch (9.52509.5377 (b). Install scissors link to scissors crank
mm) dia. for press fit of assembly with NAS620438D bolt,
HS626S4500 bushings. AN960C416 washers, MS178264
nut and cotter pins (Ref. Figure 801).
(5). Install HS626S4500 bushings in Torque nut to 30 40 inchpounds
inboard lugs of scissors crank with (3.39 4.52 Nm).
primer (CM318).
(6). Install new NAS77423 flanged (10). Record upgrade of PN 369D21002 main
bushings with primer (CM318) in rotor hub scissors crank assembly to
outboard lugs. PN 369D2100221 configuration per
DN46.1 in Component Record of
(7). Reidentify crank assembly as PN Helicopter Log Book.
369D2100221 on ID plate.
(11). Record upgrade of PN 369D21001 main
(8). zinc chromate rotor hub scissors assembly to PN
369D21001501 configuration per
(9). Reinstall scissors crank assembly using DN46.1 in Component Record of
new attach hardware as follows: Helicopter Log Book.
Page 803
623000 Revision 20
MAINTENANCE MANUAL
369D21204 LOWER SHOES
369H1001 BOOT
NAS620418D BOLT (2 REQD)

AN960PD416L WASHER (4 REQD)
MS178264 NUT (2 REQD) (NOTE)
MS24665153 COTTER PIN (2 REQD)
369D2100221 CRANK ASSEMBLY
NOTE:
TORQUE NUT 30 60 INCHPOUNDS (3.39 6.78 NM). G633005A
Figure 802. Installation of 369D2100221 Crank to Hub Lower Shoes

5. Mixer Controls Rework (a). Chamfer 369D210023 scissors crank
and 369A1003 link assembly per
dimensions shown (Ref. Figure 803).
(Ref. Figure 803) The following lists
instructions and criteria for rework of the (b). Touch up reworked area with chemi-
mixer controls to preclude interference cal film (CM206) and refinish with
between mixer components. Rework is primer (CM318) and black paint
applicable to 369D helicopter, Serial No. (CM305).
0001D thru 0129D only, unless already
(c). Using permanent ink stamp
accomplished, and is to be performed prior to
(CM312), reidentify scissors link part
rigging the main rotor controls.
number as 369A1003501.
(d). Apply a coat of varnish (CM314) over
Consumable Materials ink stamp.
(2). Rework installed 369D27611 rotating
Item Nomenclature
swashplate as follows:
CM206 Chemical coating (a). Chamfer 369D27611 swashplate per
CM305 Lacquer, acrylic dimensions shown (Ref. Figure 803).
CM312 Ink stamp, permanent (b). Touch up reworked area with chemi-
CM314 Varnish, moisture resistant cal film and refinish with primer and
black paint.
CM318 Primer
(c). Using permanent ink stamp, reiden-
tify rotating swashplate assembly
part number as 369A27611501.
(1). Remove and rework the 369D210023
scissors crank assembly and scissors (d). Apply a coat of varnish over ink
link assembly as follows: stamp.
Page 804
Revision 20 623000
MAINTENANCE MANUAL
(3). Remove and rework 369N2664 collec- (d). Apply a coat of varnish over ink
tive mixer bellcrank and 369N2670 stamp.
lateral mixer bellcrank as follows:
(a). Chamfer collective and lateral NOTE: The 369N2666503 longitudinal mixer
bellcrank assemblies per dimensions idler is compatible installed with the
shown (Ref. Figure 803). 369N2668 basic longitudinal mixer bell-
crank only. If the 369N2666505 idler is in-
(b). Touch up reworked area with chemi- stalled, the 369N2668503 bellcrank must
cal film and refinish with primer and be used.
black paint.
(c). Using permanent ink stamp, reiden- (4). Reinstall removed components.
tify collective bellcrank part number
as 369N2664501; reidentify lateral
bellcrank part number as (5). Perform rigging of main rotor controls
369N2670501. (Ref. Sec. 671000).
Page 805
623000 Revision 20
MAINTENANCE MANUAL
0.38 IN.
0.080 IN. (2.032 MM) X 45
CHAMFER AND BLEND
A A (9.652 MM)
BOTH ENDS SMOOTHLY CHAMFERED ZONE
(TYP 4 PLACES)
0.38 IN. (9.652 MM)
369D21002
ROTOR SCISSORS SECTION AA 0.20 IN. (5.08 MM)
0.25 IN. (6.35 MM)
HUB CRANK
(TYP 4 PLACES)
LOWER
SHOE
(TYP BOTH SIDES)

0.040 IN. (1.016 MM)
0.25 IN.
0.060 IN. (1.524 MM) CHAMFER
(6.35 MM)
BLEND BOTH ENDS
AT 0.25 IN. (6.35 MM)
B
WIDTH SMOOTHLY
369A1003
SCISSORS 0.25 IN.
LINK (6.35 MM)
SECTION BB (TYP BOTH SIDES)

B
0.040 IN. (1.016 MM) CL OF 0.625 IN.
X 45 CHAMFER (15.875 MM)
0.060 IN. (1.524 MM)
SLOT
BLEND BOTH ENDS
SMOOTHLY
LONGITUDINAL
CONTROL
MIXER LINK
LONGITUDINAL 369D27611 ROTATING

PITCH IDLER SWASHPLATE
COLLECTIVE PITCH
MIXER BELLCRANK
COLLECTIVE PITCH
CONTROL ROD
0.10 IN. (2.54 MM) X 30
CHAMFER, BLEND
BOTH ENDS WITH
2.25 IN. (5.715 CM) SMOOTH RADIUS TO
LONGITUDINAL PITCH (TYP) 2.25 IN. (5.715 CM) DIM.
CONTROL ROD LATERAL MIXER C 0.10 IN. (2.54 MM)
BELLCRANK (TYP BOTH SIDES
C 1.50 IN. (3.81 CM)
(TYP FAR SIDE)
SECTION CC
G6230061A
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 1 of 2)
Page 806
Revision 20 623000
MAINTENANCE MANUAL
369N2666 LONGITUDINAL
PITCH IDLER 369A7607 LONGITUDINAL
CONTROL MIXER
369N2670 MIXER BELLCRANK

LATERAL MIXER STATIONARY
BELLCRANK SWASHPLATE
CHAMFER 0.15 IN. (3.81 MM)

0.040 IN. (1.016 MM) X
0.20 IN. (5.08 MM)
MIXER LINK BLEND BOTH ENDS
SMOOTHLY
1.50 IN. (3.81 CM)

1.68 IN. (4.2672 CM)
MIXER
SUPPORT
BRACKET 369N2664 COLLECTIVE
PITCH MIXER BELLCRANK
CHAMFER 0.080 IN. (2.032 MM)

MAX X 0.180 IN. (4.57 MM)
BLEND BOTH ENDS SMOOTHLY
0.25 IN. (6.35 MM)
MAST BASE (TYP) 1.62 IN. (4.1148 CM)
1.50 IN. (3.81 CM) 1.75 IN. (4.445 CM)
1.75 IN. (4.445 CM)
0.180 IN.
(4.57 MM)
0.425 IN. (10.795 MM)

32 0.440 IN. (11.176 MM)
6 0.45 IN. (11.43 MM)
(TYP 4 PLACES) 0.48 IN. (12.19 MM) R
4.375 IN. (TYP 4 PLACES)
(11.1125 CM) 0.48 IN. (12.19 MM) R
(TYP)
30
(TYP 4 PLACES) 0.50 IN. (12.70 MM) R
G6230062A
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 2 of 2)

623000 Revision 20
MAINTENANCE MANUAL
Section
623060
Swashplate and
Mixer (600N)
MAINTENANCE MANUAL

1. Main Rotor Swashplate Do not strike rotating swash-
CAUTION plate or bearing assembly (Ref.
Figure 403) with tools or in any way deface
(Ref. Figure 403) The main rotor swashplate these components, the rotating swashplate
includes a rotating swashplate, stationary is a stressed part. Use particular care to pro-
swashplate, bearing and retainer and one tect teflon liner in bearing bore. A damaged
counterweight. The rotating swashplate swashplate bearing must not be retained in
converts movement from the stationary service.
swashplate into rotating motion and transfers
it to the main rotor hub assembly for lift, and (8). Lift swashplate carefully up and off of
longitudinal and lateral control of the helicop- mast.
ter.
(9). To remove boot from mast, remove
selfclinching nylon strap.
2. Swashplate Replacement
B. Swashplate Installation
A. Swashplate Removal (1). If swashplate lower boot was removed,
install boot on mast (Ref. Figure 403).
(1). Tag or coloridentify six pitch control (2). Position swashplate over main rotor
rods (Ref. Figure 401) to simplify mast and carefully lower into place.
replacement at same locations.
(3). Engage upper end of boot in groove at
Failure to reinstall pitch control lower side of stationary swashplate.
CAUTION rods at correct locations may re- Secure boot with selfclinching nylon
sult in main rotor blades excessively out of strap (Ref. Figure 403).
track.
(4). Align longitudinal link with stationary
swashplate (Ref. Figure 402).
(2). Disconnect pitch control rods from
rotating swashplate. (5). Install flanged bushing, if removed,
bolt, two washers, nut and cotter pin to
secure upper end of longitudinal link.
(3). Remove scissors.
(6). Align upper ends of mixer links with
stationary swashplate. Install slotted
(4). Remove main rotor hub. bushing (if removed), bolt, two washers,
nut and cotter pin to secure each link to
(5). Disconnect longitudinal link (Ref. swashplate.
Figure 402) from stationary swash-
(7). Install scissors.
plate.
(8). Using color code, reinstall pitch control
(6). Disconnect right and left side mixer rods at same locations from which
links (Ref. Figure 402) from stationary removed.
swashplate.
(9). Check track of main rotor blades (Ref.
Sec. 181060) following any mainte-
(7). Remove protective boot from groove in nance activity that could result in a
lower side of stationary swashplate dimensional variation affecting rigging
(Ref. Figure 403). or tracking.
Page 401
623060 Revision 20
MAINTENANCE MANUAL
ROTOR HUB
LOWER SHOE
WASHERS
(NOTE 4) BEARING
SLOTTED BUSHING
(NOTE 1) SCISSORS CRANK WASHERS
(NOTE 4)
BUSHING
CLOSE TOLERANCE SCISSORS LINK

BOLT (NOTE 5)
BEARING
PITCH CONTROL
ROD (NOTE 2)
SLOTTED BUSHING
(NOTE 1) ELASTOMER RING
ROTATING ELASTOMER RING

SWASHPLATE
INTERRUPTER
SLOTTED BUSHING
(NOTE 1)
COLLECTIVE LINK
ASSEMBLY
LONGITUDINAL
LINK ASSEMBLY 6.25 IN.
(15.875 CM)
(NOTE 3)
LATERAL CONTROL 0.040 IN. (1.016 MM) MAX

LINK ASSEMBLY ALLOWABLE LOOSENESS
AT INSTALLATION, ROD
SLOTTED BUSHING ENDS TO BE PARALLEL
(NOTE 1) WITH MATING CLEVIS
1.30 IN. (3.302 CM)

(TYP UPPER BEARING ONLY)
NOTES:
1. END OF SLOTTED BUSHING MUST PROTRUDE MINIMUM OF
0.010 IN. (0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. COLOR CODED TO MATCH BLADE.
3. OPTIMUM INITIAL SETTING (SIX PLACES).
4. AS REQUIRED TO FILL GAP.
5. BOLT HEADS TO FACE INWARD.
6G62031B
Figure 401. Pitch Control Rods and Swashplate Scissors Installation
Page 402
Revision 27 623060
MAINTENANCE MANUAL
3. Controls Mixer (1). Position support bracket over forward

lug on mast base.
Controls mixer includes links, bellcranks,
idlers, support bracket and fasteners to secure (2). Install two aft bolts and washers in
these components in place and to the control support bracket and mast base. Install
rods and main rotor swashplate. two thin washers and nuts; torque nuts
to 80 100 inchpounds (9.04 11.30
4. Controls Mixer Replacement Nm) plus drag torque.
A. Controls Mixer Removal (3). Using ball hole gage and standard
(Ref. Figure 402) micrometer, check that misalignment
between forward bolt hole bore in
(1). Remove air intake forward fairing for support bracket and bore in mast base
access. lug is 0.015 inch (0.381 mm) or less.
(2). Disconnect upper ends of collective, NOTE: If necessary, loosen aft two bracketto
lateral and longitudinal control links fitting nuts, position support bracket to
(Ref. Figure 401). minimize misalignment and retighten nuts.
NOTE: Control links are attached by slightly (4). Install mixer support attaching bushing
different length bolts. Reinstall each bolt in in bracket and mast base lug.
its bellcrank following control rod removal
to simplify reinstallation at correct loca- (5). Check that sleeve bushing is in place;
tions. then install bolt, two washers and nut.
(3). Remove mixer links. (Mixer link (9.04 11.30 Nm).
bearings are not replaceable.)
(6). Position longitudinal pitch idler and
(4). Disconnect longitudinal link from
collective pitch mixer bellcrank on
stationary swashplate.
support bracket. Position washer
(5). Remove longitudinal control mixer link. between right side of longitudinal pitch
idler bearing and center bearing of
(6). Disconnect lateral mixer bellcrank from mixer support bracket. Install left
collective pitch mixer bellcrank. hand bearing, with attaching hardware.
(7). Remove connecting hardware (includ- (7). Position lateral bellcrank between
ing flanged bushing) from each side of collective pitch mixer bellcrank bear-
longitudinal pitch mixer bellcrank. ings and install attaching hardware.
Carefully remove bellcrank. Retain any
shims that may be installed. (8). Position longitudinal pitch mixer
bellcrank with collective pitch mixer
(8). Remove bolt from hingeline of support bellcrank; insert two flanged bushings.
bracket, longitudinal pitch idler and Install two bolts.
collective pitch mixer bellcrank.
Separate the three parts. (9). Push longitudinal bellcrank to one side
and measure gap between bellcrank
(9). Remove mixer support bracket from and bearings in collective pitch bell-
mast base. crank.
To prevent washing dirt into
CAUTION bearings, or washing grease out (10). Using HS50792646 laminated wash-
of bearings, do not permit solvent to enter er(s), shim evenly to take up gap.
bearings when cleaning mixer control com- (11). Insert flanged bushings, bolts, six
ponents. washers (two under each nut) shims
B. Mixer Controls Installation and nuts. Torque nut to 30 40 inch
pounds (3.39 4.52 Nm) and install
(Ref. Figure 402) cotter pin.
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623060 Revision 31
MAINTENANCE MANUAL
BUSHING
(NOTE 2) LONGITUDINAL CONTROL STATIONARY
MIXER LINK SWASHPLATE
LONGITUDINAL BUSHING
PITCH IDLER MIXER LINK (NOTE 2)
LONGITUDINAL
FLANGED LINK
BUSHING (NOTE 3)
STATIONARY BEARING
SWASHPLATE
LATERAL MIXER (NOTE 1)

BELLCRANK
(NOTE 5) MIXER
LINK
WASHER
(NOTE 1)
BEARING
(NOTE 1) BUSHING BUSHING
(NOTE 2) (NOTE 2)
FLANGED
BUSHING BEARING
MIXER SUP- (NOTE 4)
PORT AT-
BEARING BEARING
TACHING
BUSHING
(NOTE 6)
NOTE 7
MIXER
SUPPORT
BRACKET
BEARING
SLEEVE COLLECTIVE PITCH
BUSHING MIXER BELLCRANK
BEARING
FLANGED BUSHING LONGITUDINAL
(NOTE 4) PITCH MIXER
BELLCRANK
MAST BASE
TWO IDENTIFYING LOCATORS

ONE IDENTIFYING LOCATOR (FACING UP AND OUT)
(FACING OUT) L/H SIDE ONLY R/H SIDE ONLY
NOTES:
1. DIRECTION OF BOLT OPTIONAL.
2. EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN.
(0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE LEFTHAND RIGHTHAND MIX-
OUTSIDE OF PART AFTER NUT IS TIGHTENED. MIXER LINK ER LINK
3. LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY. (600N76361/9) (600N76363/11)
4. MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.
5. PART MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.
(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL,
LONGITUDINAL LINK
REFER TO SECTION 204000).
6. INSTALL BUSHING AFTER THE TWO AFT ATTACHING BOLTS
WITHOUT EXCESSIVE MISALIGNMENT, 0.015 IN. (0.381 MM). MAST CL
7. USING HS50792646 SHIMS, SHIM EQUALLY TO REMOVE GAP.
MIXER LINK IDENTIFICATION
FOR PROPER INSTALLATION 6G62032C
Figure 402. Controls Mixer Assembly
Page 404
Revision 35 623060
MAINTENANCE MANUAL
(12). Position longitudinal control mixer link (2). Remove cotter pin, nut, washer, and
between longitudinal pitch idler and bolt from each leg of scissors crank.
longitudinal pitch mixer bellcrank; Disconnect crank from hub lower shoe.
check that two slotted bushings are in
place. Install bolt, three washers (two (3). Remove cotter pin, nut, washer, and
under each nut), nut and cotter pin at bolt connecting scissors link to swash-
each end of link. plate; remove scissors.
B. Scissors Installation
(13). Position longitudinal link between
longitudinal pitch mixer bellcrank (Ref. Figure 401)
bearings. Install attaching hardware.
(1). Place scissors link in mounting posi-
NOTE: In the following step, ensure mixer tion, chamfered edge of link must face
links are not installed inverted and are outboard.
installed in the correct position (Ref. (2). Check that slotted bushing is in
Figure 402, View A). swashplate web and install attaching
hardware. Torque nut to 15 20
(14). Position mixer links in stationary
swashplate and lateral mixer bellcrank;
check that slotted bushings are in Scissors crank must be posi-
place. Install attaching hardware. CAUTION tioned (Ref. Figure 401) with de-
cal up and proper direction towards lower
(15). Place collective, lateral longitudinal side lugs.
control links (Ref. Figure 401) in
mounting position; check that slotted NOTE: Ensure cranktohub lower shoe lugs
bushing is in place. Install attaching are not preloaded.
hardware.
(3). Position scissors crank on hub lower
(16). Install air intake forward fairing. shoe lugs; install connecting hardware.
Install bolts with bolt heads facing
(17). Check rigging of collective and cyclic inward and a washer under head of bolt
controls. (Ref. Figure 401). Torque nuts to 30
5. Scissors NOTE: Shim washers may be required on
shouldered bushing side of clevis.
The scissors provide a movable connection
between the rotating swashplate and main (4). Position elastomer rings and lower end
rotor hub. of pitch control rod in swashplate lug
and install attaching hardware. (Nut is
6. Scissors Replacement to be adjacent to bushing in swash-
plate.) Torque nut to 30 60 inch
A. Scissors Removal pounds (3.39 6.78 Nm).
(Ref. Figure 401) 7. Scissors Link Replacement
Removal of all pitch control rods Consumable Materials

CAUTION is recommended prior to scissors (Ref. Section 910000)
removal. Failure to observe this precaution Item Nomenclature
could result in damage to pitch control rods,
swashplate and/or hub. Ensure all rods are CM103 Solid film lubricant
colorcoded or marked so they will be rein-
stalled in the correct location. (1). Remove cotter pin, nut, washer and bolt
that join link and crank.
(1). Disconnect lower end of pitch control
rod that is in line with scissors link in (2). Remove two bushings from link only if
rotating swashplate. replacement is necessary.
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623060 Revision 35
MAINTENANCE MANUAL
(3). Do not remove bearing from link, (2). Remove pitch control rod and Oring.
replace complete link if bearing is
defective. B. Pitch Control Rod Installation
NOTE: Install new bushings using solid film lu- (Ref. Figure 401)
bricant (CM103); do not use zinc chro-
At installation, install rod at
mate. CAUTION correct color code location. Cen-
(4). If bushings were removed at disassem- ter bearing rodends between attach clevis. If
bly, install new bushings. After installa- rod length is changed, blades must be
tion, dimension between outer faces of tracked.
bushings should be 1.5791.586 inches
(4.0114.028 cm). (1). If actual rod length is incorrect or
either actual or required rod length is
(5). Align bore of link with bore of crank; unknown, preset link length to opti-
install bolt, washer and nut. Torque nut mum length of 6.25 inches (15.88 cm).
Nm); install cotter pin. NOTE: Install both pitch change rod bolts in
direction of rotation.
8. Pitch Control Rods
(2). Install rod with elastomeric rings on
Six pitch control rods transfer pitch control both sides of lower bearing.
from the rotating swashplate to the main rotor
blades. NOTE: Add washers as required to align nut
with cotter pin hole.
9. Pitch Control Rod Replacement
(3). Torque upper nut to 100 130 inch
A. Pitch Control Rod Removal pounds (11.30 14.69 Nm).
(Ref. Figure 401) NOTE: Bushing must project 0.0100.060 inch
(0.2541.524 mm) after nut is torqued.
NOTE:
D If rod is not to be reinstalled, but is to be (4). Torque lower nut to 30 60 inch
replaced, measure and record length of pounds (3.39 6.78 Nm).
removed link. Optimum length may have
been changed at previous rigging; pread- (5). Secure nuts with cotter pins.
just replacement link to length of link re-
(6). Rotate pitch control rod assembly fore
moved.
and aft to ensure clearance exists
D Rods are color coded for reinstallation at between rod end bearing and pitch
correct locations. If more than one rod is housing clevis at both ends.
being removed and color coding is not vis-
ible, identify each by color or similar (7). If installation is final and tracking is
means to points of connection to simplify not required, safetywire rod ends to rod;
reinstallation. ensure rod ends are centered.
(1). Remove cotter pin, nut, washer and bolt (8). As necessary, repeat above procedures
from each end of pitch control rod. for remaining pitch control rods.
Page 406
Revision 35 623060
MAINTENANCE MANUAL
BEARING
ASSEMBLY
ROTATING BALANCE
SWASHPLATE WEIGHT
INTERRUPTER INTERRUPTER
STATIONARY
SWASHPLATE
DRAIN HOLES
(HIDDEN)
INDEX
PROTRUSIONS
DRAIN HOLES
(2 PLACES)
STATIONARY
SWASHPLATE
GROOVE
BOOT
NYLON STRAP
MAST
6G62033
Figure 403. Main Rotor Swashplate

623060 Revision 20
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Swashplate Inspection (a). Maximum radial play between
sliding surface liner and stationary
mast is 0.020 inch (0.508 mm).
(Ref. Section 910000) (b). Maximum axial play between spheri-
Item Nomenclature cal ball and teflon liner is 0.010 inch
(0.254 mm).
(c). If play is suspected in double row ball
bearing, turn rotating swashplate
When cleaning swashplate for until arms line up with those of
CAUTION inspection, prevent solvent from stationary swashplate and check
entering either spherical ball bearing or motion between arms at control bolt
double row ball bearing. Use cloth moist- in stationary swashplate.
ened in alcohol (CM217) to wipe clean
(d). Maximum total vertical movement of
spherical ball, ball bore liner and exterior of
0.015 inch (0.381 mm) is allowable.
double row ball bearing.
(e). If movement limit is exceeded replace
NOTE: double row ball bearing (Ref. COM).
D Stationary swashplate may be con- (5). Inspect swashplate spherical and
structed of either magnesium or alumi- double row ball bearings for condition.
num alloy. For corrosion control and iden-
tification of magnesium and aluminum (a). Nicks and dents that do not deform
alloys (Ref. Sec. 204000). ID chamfered edge of hard anodized
ball, and not more than 0.10 inch
D In the following inspection, the rotating (0.254 mm) deep along spherical ball
and stationary swashplates must be dis- surface from edge are allowed.
connected (Ref. Swashplate and Mixer
Removal/Installation). (b). Scratches, any length, on OD of
spherical ball are allowed if they are
no deeper than 0.010 inch (0.254
(1). Inspect swashplate bearing assembly
mm) or wider than 0.060 inch (1.524
(Ref. Figure 403 for evidence of binding
mm).
in either radial or axial movement.
(c). Not more than two scratches are
(2). Inspect teflon liners for condition. permitted in a one inch wide area.
(6). Check existing preload on spherical
(3). Ensure that all flexible rubber seals
bearing.
enclosing ball bearing races are in
place; inspect for deterioration and (a). Hook spring scale over one of the
indication of grease leakage. (For bolts securing stationary swashplate
bearing maintenance information to the bearing flange.
(including lubrication), Ref. COM).
(b). With stationary swashplate in
motion, drag should be no more than
NOTE: New swashplate bearing assembly nor-
30 pounds (13.61 kg). (Use average
mally shows some signs of grease leakage
of four readings taken 90 degrees
for first 1015 hours of operation after in-
apart).
stallation.
(c). If readings are more than 30 pounds
(4). Inspect swashplate spherical ball and (13.61 kg), clean spherical bearing
double row ball bearing for radial or with isopropyl alcohol and recheck
axial play. drag.
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623060 Revision 32
MAINTENANCE MANUAL
(d). Repair damage or replace bearings mixer link for binding, play in link bore
(Ref. COM). and wear. Wear limit is 0.008 inch
(0.203 mm) radially and 0.040 inch
(7). Check double row ball bearing for (1.016 mm) axially. Replace complete
serviceability, with seals in place and mixer link if bearings are faulty.
unbroken. Inspect bearings in other linkage for
(a). Check for correct operation and binding and looseness in mating bores.
lubrication.
3. Scissors Inspection
(b). Bearing must rotate smoothly,
(Ref. Figure 401)
without roughness. Binding or
catching should not exist when Any evidence of failure,
bearings are rotated 360. WARNING damage, or deformation of
(c). Replace defective double row ball crank or link is justification for re-
bearings (Ref. COM). placement of either crank, link, or com-
plete scissors assembly. Failure of any
(8). Perform careful visual inspection of of these components in flight can result
stationary and rotating swashplate for in failure of movable flight controls,
cracks, wear in bolt and bushing bores, loss of helicopter, and possible injury
and fork inner surfaces; and for or loss of life.
corrosion, nicks and dents.
(1). Inspect crank and link for evidence of
(9). Perform dye penetrant check on impact damage and deformation. If
questionable areas. condition is questionable, perform
fluorescent dye penetrant inspection.
(10). Check that counterweights are securely
bonded in rotating swashplate. (2). Inspect bearings for binding, looseness
in bore and wear. Maximum wear limits
2. Mixer Controls Inspection are 0.010 inch (0.254 mm) radial and
0.020 inch (0.508 mm) axial.
(Ref. Figure 402)
(1). Inspect all bushings for security of fit. 4. Pitch Control Rod Inspection
(2). Inspect longitudinal link, support (Ref. Figure 401)

bracket, longitudinal control mixer link, Ensure that rod end bearings
mixer links, longitudinal pitch idler, CAUTION are centered and do not contact
longitudinal pitch mixer bellcrank, attach clevis.
lateral bellcrank and collective pitch
mixer bellcrank for scratches, cracks, (1). Visually inspect upper and lower rod
corrosion and similar surface defects. end bearings for evidence of excessive
For components that are questionable, axial play, 0.040 inch (1.016 mm)
perform fluorescent dye penetrant maximum; and for any extrusion,
inspection. displacement or damage to the bearing
teflon liner.
(3). Inspect spherical, teflon (or equivalent)
lined, bearings in longitudinal link, (2). Replace rod end bearing if discrepan-
mixer link, and longitudinal control cies are noted.
Page 602
Revision 32 623060
MAINTENANCE MANUAL

REPAIRS
1. Swashplate Repairs be restored on magnesium and alumi-
num parts.
(Ref. Figure 403) Disassembly other than as
illustrated is considered a part of swashplate (7). Replace defective bearings and bush-
overhaul (Ref. COM). If tracking interrupters ings, except swaged spherical bearings
are to be removed, mark them for reinstalla- in mixer links which require link
tion at original locations. replacement. Remove bearings or
bushings by pressing them out. Install
2. Mixer Controls Repair new bearing with surface primer and
grade A locking compound (CM321 and
(Ref. Figure 402) CM431).
NOTE: Lefthand bearing in support bracket is
Consumable Materials not supplied as part of bracket. This bearing
(Ref. Section 910000) is installed at time support bracket and lon-
Item Nomenclature gitudinal pitch idler are assembled. Install
CM321 Surface primer locking compound new bearing by seating flush with inner face
CM431 Sealing, locking and retaining compound of support bracket flange.
3. Scissors Bushing and Bearing
Replacement
NOTE: Following depth limits are total limits, (Ref. Figure 401)
including effects of all previous repairs to
any given area.
(1). Repair minor surface defects such as (Ref. Section 910000)
scratches, nicks and corrosion using Item Nomenclature
abrasive cloth (CM802), grade 400 CM103 Solid film lubricant
600 to smooth out and blend in such CM222 1,1,1Trichloroethane
defects.
CM318 Primer
(2). Cast and forged surfaces may be CM321 Surface primer locking compound
reworked to depth of 0.020 inch (0.508 CM431 Sealing, locking and retaining compound
mm).
(3). Flat machined surfaces, except clevis (1). Remove cotter pin, nut, washer, and
inner ears, may be reworked to depth of bolt that join link and crank.
0.015 inch (0.381 mm). Clevis inner ear
surfaces may be reworked to depth of (2). Remove two bushings from link only if
0.020 inch (0.508 mm). replacement is necessary.
(4). Machined holes may have 0.003 inch (3). Do not remove bearing from link.
(0.076 mm) removed from bore wall in Replace complete link if bearing is
an area no greater than 15 percent of defective.
circumference and 50 percent of depth. (4). Remove slotted bushings and bearings
from crank, only if replacement is
(5). All edges may have 0.030 inch (0.762 necessary.
holes which are limited to 0.010 inch During cleaning, do not allow
(0.254 mm) chamfer. CAUTION solvent to enter bearings.
(6). All rework must be smoothly blended (5). Install new bushings using solid film
into adjacent surfaces and finish must lubricant (CM103); do not use zinc
Page 801
623060 Revision 20
MAINTENANCE MANUAL
chromate. Press in bushing until end (e). Remove excess sealant. Do not allow
is flush with inside surface of crank sealant to enter bearing race.
inboard ears.
(6). If bearings were removed from crank at (f). Apply a small fillet of sealant to the
disassembly, reinstall using the faying edges of bearing housing. Use
following procedure: cellophane or masking tape to
exclude air and allow sealant to cure
NOTE: Do not allow sealant to enter bearing for 24 hours at ambient temperature
race. or force cure by heating to
(a). Clean bearing outer face, counterbore 140160F (6072C) for one hour
and faying surfaces with trichloroe- prior to use of assembly.
thane (CM222). Do not allow trichlo-
roethane to enter bearing. (7). If bushings were removed from link at
(b). Coat the faying surfaces with surface disassembly, install new bushings.
primer (CM321) as per manufactur- After installation, dimension between
ers instructions. outside faces of bushings should be
1.5791.586 inches (4.01074.0284 cm).
(c). Apply locking compound (CM431) to
faying surfaces.
(8). Align bore of link with bore of crank;
(d). Press bearing until outer face is install bolt, washer and nut. Torque nut
seated firmly against shoulder of to 30 40 inchpounds (3.39 4.52
counterbore. Nm).
Page 802
Revision 20 623060
MAINTENANCE MANUAL
Chapter
63
Transmission and
Drive System
MAINTENANCE MANUAL
TABLE OF CONTENTS
630000 Transmission and Drive System (369D/E/FF 500/600N) . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Power Train System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101. Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
631000 Drive Shafts / Clutches / Couplings (369D/E/FF 500/600N) . . . . . . . . . . . A
1. Main Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Rotor drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . 402
3. Main Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Main Transmission Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Transmission Drive Shaft Removal (Bendix and Kamatic) . . . . . . . . . . . . . 404
B. Main Transmission Drive Shaft Installation (Bendix and Kamatic) . . . . . . . . . . 404
Figure 402. Main Transmission Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . 405
5. Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
6. Overrunning Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Overrunning Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. 369A5350 Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. 369F5450 Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . 408
7. Overrunning Clutch Subassembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Overrunning Clutch Subassembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Overrunning Clutch Subassembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8. Overrunning ClutchtoFirewall Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
9. Overrunning ClutchtoFirewall Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 410
10. Main Transmission Drive Shaft Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
11. Main Transmission Drive Shaft Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . 411
A. Main Transmission Drive Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Main Transmission Drive Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . 411
Page i
MAINTENANCE MANUAL

12. Tail Rotor Drive Shaft Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Tail Rotor Drive Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Tail Rotor Drive Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 405. 369F5468/5469 Bolt Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1. 369D25510 Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . 601
Figure 601. Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602. Main Rotor Drive Shaft Overtorque Verification Stripe . . . . . . . . . . 603
3. Main Transmission Drive Shaft Inspection (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Main Transmission Drive Shaft Inspection (Kamatic) . . . . . . . . . . . . . . . . . . . . . . . . . 604
5. Overrunning Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6. Overrunning ClutchtoFirewall Seal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
7. Bendix Tail Rotor Drive Shaft Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
8. Kamatic Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
9. Main Rotor Drive Shaft Inspection (300 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Drive Shaft Exterior Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Main Rotor Drive Shaft Corrosion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3. Main Transmission Drive Shaft Repair (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Main Transmission Drive Shaft Repair (Kamatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5. Overrunning Clutch Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
6. Overrunning ClutchtoFirewall Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
7. Main Transmission Drive Shaft Coupling Corrosion Removal . . . . . . . . . . . . . . . . . . 803
8. Bendix Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
9. Kamatic Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Page ii
MAINTENANCE MANUAL

631510 Tail Rotor Drive Shaft (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Tail Rotor Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Tail Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Tail Rotor Drive Shaft Installation with Bendix Couplings . . . . . . . . . . . . . . . . . . 401
Figure 401. Tail Rotor Drive Shaft Installation (369D/E/FF) (Sheet 1 of 3) . . . . 402
Figure 402. Tail Rotor Drive Shaft Installation (369FF) . . . . . . . . . . . . . . . . . . . . . 407
C. Tail Rotor Drive Shaft Installation with Kamatic Couplings . . . . . . . . . . . . . . . . . 408
3. Tail Rotor Drive Shaft Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
4. Tail Rotor Drive Shaft Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1. Tail Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Tail Rotor Drive Shaft Twist Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Tail Rotor Drive Shaft Inspection Markings . . . . . . . . . . . . . . . . . . . 602
Figure 602. Tail Rotor Drive Shaft Inspection Markings (Extended Tailboom) 603
3. Tail Rotor Drive Shaft Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 603. Tail Rotor Drive Shaft Damper Inspection . . . . . . . . . . . . . . . . . . . . 605
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Tail Rotor Drive Shaft Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Tail Rotor Drive Shaft Index Stripe Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
631530 NOTAR) AntiTorque System Drive Shafts (500/600N) . . . . . . . . . . . . . . . . A
1. AntiTorque System Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fan Gearbox Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fan Gearbox Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fan Gearbox Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fan Gearbox Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Fan Gearbox Drive Shaft Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Fan Gearbox and InterConnecting Drive Shafts . . . . . . . . . . . . . . . 204
5. Fan InterConnect Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Fan InterConnect Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Fan InterConnect Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. InterConnect Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. InterConnect Drive Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Transmission and Fan Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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9. Gearbox and Fan Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

10. Transmission Coupling / Fan Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Transmission Coupling / Fan Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Transmission Coupling / Fan Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Fan Interconnect Drive Shaft Coupling Installation . . . . . . . . . . . . . 207
632000 369D25100 Main Transmission (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . A
1. Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Transmission Buildup and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. 369D25100 Main Transmission Installation . . . . . . . . . . . . . . . . . . . . 202
B. Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Main Transmission Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Main Transmission Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Input Drive Assembly Oil Leakage Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Input Drive Assembly ORing Replacement . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Assembly Aid Tool for Input Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
632025 369F5100 Main Transmission (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . A
1. Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. 369F5100 Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . 202
3. Main Transmission Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. 369F5100 Main Transmission BuildUp . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Main Transmission BuildUp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Main Transmission Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Main Transmission Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Input Drive Assembly Oil Leakage Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Input Pinion ORing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Drive Assembly ORing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Input Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8. Main Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9. Main Transmission RunIn Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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632100 Main Transmission Lubrication and Cooling System

(369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Transmission Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Transmission Lubrication Pump Replacement
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Transmission Lubrication Pump Removal
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Transmission Lubrication Pump Installation
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Main Transmission Lubrication Pump Replacement
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Transmission Lubrication Pump Removal
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Transmission Lubrication Pump Installation
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Main Transmission Lubrication Pump
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. Main Transmission Lubrication Pump
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Main Transmission Filter Replacement (369D25100 Transmission) . . . . . . . . . . . . 404
5. Main Transmission Filter Replacement (369F5100 Transmission) . . . . . . . . . . . . . . 404
6. Main Transmission Scavenge Pump Replacement (369F5100 Transmission) . . . . 404
A. Main Transmission Scavenge Pump Removal (369F5100 Transmission) . . . . . . 404
B. Main Transmission Scavenge Pump Installation (369F5100 Transmission) . . . 404
7. Main Transmission Oil Cooler Bypass Valve Replacement . . . . . . . . . . . . . . . . . . . . . 405
8. Main Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Main Transmission Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Main Transmission Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. Main Transmission Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . 406
9. Main Transmission Oil Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . . 407
10. Main Transmission Oil Pressure Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 407
11. Liquid Level Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. Main Transmission CrossSection View . . . . . . . . . . . . . . . . . . . . . . 408
12. Chip Detector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
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13. Cooling Blower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Cooling Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Cooling Blower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
C. Cooling Blower Installation (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . 409
Figure 405. Cooling Blower Installation (369D25100 Transmission) . . . . . . . . . . 410
D. Cooling Blower Installation (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . 411
Figure 406. Oil Cooler Blower Installation (369F5100 Transmission) . . . . . . . . . 412
E. 369D, E, F, and 500N Cooling Blower Belt Tracking . . . . . . . . . . . . . . . . . . . . . . 413
Figure 407. Cooling Blower Belt Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1. Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Cooling Blower Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Cooling Blower Inspection (Disassembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Main Transmission Cooling Blower and Duct . . . . . . . . . . . . . . . . . . . 602
4. Cooling Blower Belt Tension Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. 369D25630 Cooling Blower Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. 369D25630 Cooling Blower CrossSection View . . . . . . . . . . . . . . . 802
2. 369D25630 Cooling Blower Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
3. 600N5630 Cooling Blower Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 802. 600N5630 Cooling Blower CrossSection View . . . . . . . . . . . . . . . . 805
4. 600N5630 Cooling Blower Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
5. Cooling Blower Cleaning (Disassembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
6. Transmission and Cooling Blower Drain Tube Repair and Replacement . . . . . . . . . 808
7. Installation of Heating System and Oil Cooling Line Standoff Clamps
(0003D 0539D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 803. Installation of Standoff Clamps Heating and Oil Cooling Lines . 810
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632200 Rotor Brake (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Rotor Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Rotor Brake Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Master Cylinder Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Rotor Brake Hydraulic System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Rotor Brake Component Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7. Master Cylinder Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8. Caliper Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 201. Troubleshooting Rotor Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . 204
1. Rotor Brake Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Master Cylinder Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Master Cylinder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. AirframeMounted Rotor Brake Components . . . . . . . . . . . . . . . . . . . 402
B. Master Cylinder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Master Cylinder Linkage Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Master Cylinder Linkage Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Master Cylinder Linkage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Master Cylinder Linkage Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Caliper Assembly, Brake Disc, and Drive Coupling Replacement
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Caliper Assembly, Brake Disc, and Drive Coupling Removal
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. TransmissionMounted Rotor Brake Components . . . . . . . . . . . . . . . 406
B. Caliper Assembly, Brake Disc and Drive Coupling Installation
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. Caliper Assembly and Brake Disc Interface
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 405. Lockwire Installation (369D25100 Transmission) . . . . . . . . . . . . . . . 408
5. Caliper Mounting Bracket Replacement (369D25100 Transmission) . . . . . . . . . . . . 409
A. Caliper Mounting Bracket Removal (369D25100 Transmission) . . . . . . . . . . . . . . 409
B. Caliper Mounting Bracket Installation (369D25100 Transmission) . . . . . . . . . . . 409
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6. Caliper Assembly, Brake Disc, and Drive Coupling Replacement
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Caliper Assembly, Brake Disc, and Drive Coupling Removal
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Caliper Assembly, Brake Disc and Drive Coupling Installation
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission) . . . . . . 411
7. Hydraulic Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Hydraulic Relief Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Hydraulic Relief Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
8. Hydraulic Tube Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Hydraulic Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Hydraulic Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
9. Rotor Brake Forward Cover Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1. Rotor Brake Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Rotor Brake Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
1. Rotor Brake Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Aircraft Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Installation Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Removing Components to be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Angle Assembly Installation (500D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
E. Master Cylinder Linkage Assembly and Mount Bracket Installation . . . . . . . . . 902
Figure 901. Locating Permanently Installed Components (Sheet 1 of 2) . . . . . . 903
F. Handle Retainer Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
G. Rivnut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Figure 902. Rotor Brake Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 906
H. Window Support Channel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
I. Caliper Mounting Bracket Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
J. Caliper Assembly, Brake Disc and Drive Coupling Installation . . . . . . . . . . . . . . . 908
Figure 903. Modifying Window Support Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
Figure 904. Hydraulic Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
Page viii
MAINTENANCE MANUAL

K. Master Cylinder Assembly Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
Figure 905. Positioning Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
L. Hydraulic Relief Valve Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
M. Hydraulic Tube Assemblies Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
N. Rotor Brake Installation Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Figure 906. Reworking Master Cylinder Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
O. Installing Interior Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
P. Map Case Assembly Modification and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 913
Q. Convenience Panel Cover Assembly Modification and Installation . . . . . . . . . . . 913
R. Rotor Brake Forward Cover Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 913
Figure 907. Modifying Map Case Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 914
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 1 of 2) . . . . 915
S. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
632510 Tail Rotor Transmission (Two and Four Blade) (369D/E/FF) . . . . . . . . . . A
1. Tail Rotor Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tail Rotor Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tail Rotor Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tail Rotor Transmission Stripping/Buildup . . . . . . . . . . . . . . . . . . . . 202
3. Tail Rotor Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Replacement of Liquid Level Plug and BreatherFiller . . . . . . . . . . 204
4. Tail Rotor Transmission Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Tail Rotor Transmission Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Tail Rotor Transmission Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Input and Output Gearshaft Cover Oil Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Tail Rotor Transmission Housing Assembly Rework (PN 369D25401) . . . . . . . . . . 206
Figure 203. Tail Rotor Transmission Mount Stud Limits . . . . . . . . . . . . . . . . . . . . 206
Figure 204. Rework of Tail Rotor Transmission Housing Assembly . . . . . . . . . . . 207
Page ix
MAINTENANCE MANUAL

632530 NOTAR) AntiTorque System Fan Transmission (500/600N) . . . . . . . . . . A

Maintenance practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Fan Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fan Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fan Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fan Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Fan Transmission Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Fan Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Tube Support Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Fan Transmission Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fan Transmission Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 204
633000 Main Rotor Static Mast (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Rotor Static Mast Replacement (369D25100 Transmission Installation) . . . 201
A. Main Rotor Static Mast Removal (369D25100 Transmission Installation) . . . . . 201
B. Main Rotor Static Mast Installation (369D25100 Transmission Installation) . . 201
Figure 201. Main Rotor Mast and Support Structure
(369D25100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Main Rotor Static Mast Replacement (369F5100 Transmission Installation) . . . . 203
A. Main Rotor Static Mast Removal (369F5100 Transmission Installation) . . . . . . 203
B. Main Rotor Static Mast Installation (369F5100 Transmission Installation) . . . 203
4. Main Rotor Static Mast Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Main Rotor Mast and Support Structure
(369F5100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Main Rotor Mast Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . 206
Page x
MAINTENANCE MANUAL
Section
630000
Transmission and
Drive System
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
TRANSMISSION AND DRIVE SYSTEM

FAULT ISOLATION
1. Power Train System 2. Power Train System Troubleshooting
(Ref. Figure 101) The power train system,
starting at the engine power takeoff pad, (Ref. Table 101) Diagnose and repair power
consists primarily of the overrunning clutch, train system malfunctions using procedures as
drive shafts, and transmissions. follows.
Table 101. Troubleshooting Power Train System
Main drive shaft vibrates Coupling flange bolts on main drive Retorque bolts to 50 70
excessively. (For serviceability shaft are loose. inchpounds (5.65 7.91 Nm).
limits, refer to Section 631000).
Excessive noise or vibration in Defective impeller or damaged Replace impeller or scroll (Ref. Sec.
cooling blower. scroll. 632100).
Main drive shaft turns erratically or Defective overrunning clutch. Replace overrunning clutch (Ref.
not at all. Sec. 631000).
Main transmission requires Leakage at main transmission input If leakage is found at input shaft or
frequent addition of oil. or output seals. tail rotor shaft, replace seal
according to instructions (Ref. COM).
If leakage is at main rotor drive shaft,
replace transmission (Ref. Sec.
632000).
Oil leak around accessory drive Tighten cover or replace

cover. transmission (Ref. Sec. 632000).
Oil temperature warning light Defective oil temperature sender. Replace oil temperature sender (Ref.
comes on when oil temperature is Sec. 632100).
normal.
Oil temperature warning light Defective cooling blower. Repair or replace cooling blower
comes on when oil temperature is (Ref. Sec. 632100).
abnormally high.
Low or high oil level in Establish correct oil level (Ref. Sec.
transmission. 120000).
Defective lubrication pump. Replace pump (Ref. COM).
Defective oil cooler bypass valve. Replace valve. (Ref. Sec.

632100).
Defective bearings or gears. Replace transmission (Ref. Sec.

632000).
Page 101
630000 Revision 28
MAINTENANCE MANUAL
Table 101. Troubleshooting Power Train System (Cont.)

NOTE: Noise that indicates a defective transmission should not be confused with normal gear backlash noise at
rundown or low rpm and power conditions.
Excessive noise in main Inadequate oil supply. Service main transmission (Ref. Sec.
Defective bearings or gears. Replace transmission (Ref. Sec.

632000).
Oil pressure warning light (low oil Low oil in main transmission. Service main transmission (Ref. Sec.
pressure) remains lighted at above 120000).
55% N2.
Defective oil pressure switch. Replace oil pressure switch (Ref.
Sec. 632100).
Defective lube pump. Replace lube pump (Sec.

632000).
Filter clogged. Replace filter (Ref. Sec. 632100).
369F5100 Transmission impending Filter clogged. Reset indicator. On second popup,

bypass indicator popped. replace filter (Ref. Sec. 632100).
Defective differential pressure Replace differential pressure

indicator. indicator (Ref. COM).
369F5100 Transmission impending Defective differential pressure Replace differential pressure

bypass indicator popped in less indicator. indicator (Ref. COM).
than 100 hours since filter change.
Tail rotor drive shaft damper Damper out of adjustment. Adjust damper (Ref. Sec. 631500).
vibrates.
Damper defective. Replace damper (Ref. Sec.
631500).
Tail rotor drive shaft bent or dented. Replace defective drive shaft (Ref.
Sec. 631500).
Tail rotor out of balance. Adjust tail rotor balance (Ref. Sec.
181000).
Tail rotor transmission output shaft Worn or damaged bearing or gear Replace tail rotor transmission (Ref.
vibrates. in tail rotor transmission. Sec. 632510).
Excessive shaft wobble or end play Replace tail rotor transmission (Ref.
(Ref. Sec. 631510). Sec. 632510).
Excessive noise in tail rotor Inadequate oil supply. Service tail rotor transmission (Ref.
transmission. Sec. 120000).
Defective bearings or gears in tail Replace tail rotor transmission (Ref.

rotor transmission. Sec. 632510).
Page 102
Revision 29 630000
MAINTENANCE MANUAL
Table 101. Troubleshooting Power Train System (Cont.)

Chip detector caution light on. Metallic chips in either main Inspect and clean chip detector
transmission, fan transmission or magnetic plugs. If there are heavy
tail rotor transmission. chip deposits (chips larger than 1/8
inch in any direction), replace
transmission. If chips are smaller,
drain and refill transmission with new
oil. Reinstall chip detector and check
after four hours of flight. If more
chips are found, replace
transmission (main Sec. 632000
or 632025; tail rotor Sec.
632510; fan 632530).
Chip detector caution light is on, Defective chip detector circuit Troubleshoot chip detector circuit
but no chips are on detector. components. (Ref. CSPHMI3).
NOTE: High frequency vibrations in helicopter can also be caused by components in other systems.
High frequency vibrations. Loose tail rotor drive shaft Tighten coupling bolts (Ref. Sec.
coupling(s). 631500).
Tail rotor drive shaft coupling Shim correctly (Ref. Sec. 631500).
shimmed improperly.
Loose, mismatched or bottomed Tighten or install correct hardware

hardware retaining tail rotor drive and be sure hardware is installed
shaft coupling to main correctly (Ref. Sec. 631500).
transmission.
Cooling blower impeller has cracks, Replace impeller (Ref. Sec.

loose rivets, defective blades or 632100).
other damage.
Tail rotor drive shaft damper out of Adjust damper friction (Ref. Sec.
adjustment. 631500).
Defective overrunning clutch. Replace overrunning clutch (Ref.

Sec. 631000).
Tail rotor drive shaft damaged. Replace shaft (Ref. Sec. 631500).
Abnormal drag in drive system. Excessive drag in main Replace transmission (Ref. Sec.
NOTE: Drag is excessive when force required to rotate transmission input shaft exceeds 25 inchpounds (2.82
Nm) with all shafting disconnected and transmission temperature between 50F (10C) and 100F (38C).
Page 103
630000 Revision 30
MAINTENANCE MANUAL
TAIL ROTOR TRANSMISSION
TAIL ROTOR DRIVE

MAIN ROTOR DRIVE SHAFT DAMPER
SHAFT
MAIN TRANSMISSION
TAIL ROTOR DRIVE SHAFT
COOLING BLOWER
MAIN TRANSMISSION
DRIVE SHAFT
FAN TRANSMISSION
DRAIN LINE
FAN GEARBOX
DRIVE SHAFT
ANTITORQUE FAN
FAN INTERCONNECT
DRIVE SHAFT
G630000A
Figure 101. Power Train System
Page 104
Revision 28 630000
MAINTENANCE MANUAL
Section
631000
Drive Shafts /
Clutches / Couplings
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
DRIVE SHAFTS / CLUTCHES / COUPLINGS

1. Main Rotor Drive Shaft B. Main Rotor Drive Shaft Installation
The main rotor drive shaft is a shotpeened,

steel alloy forging having a nitrided spline at Special Tools
one end that mates with the transmission (Ref. Section 910000)
output shaft, and a flanged opposite end that Item Nomenclature
attaches to the rotor hub with seven bolts and ST704 Adapter, torque wrench
three eyebolts.
2. Main Rotor drive Shaft Replacement Damage to main rotor drive

CAUTION shaft or transmission splines
can occur during installation. Care should
(Ref. Figure 401)
be taken while meshing driveshaft splines
into transmission output splines to prevent
When removing or installing the
CAUTION main rotor drive shaft external
damage.
wrenching bolts or eyebolts, always hold (1). Slowly and carefully lower drive shaft
bolts stationary while installing or remov- through main rotor hub and mast until
ing nuts. Never turn externalwrenching rotor shaft splines and transmission
bolts or eyebolts while inserting or removing shaft splines engage.
from drive shaft holes.
(2). Rotate hub to align holes in flange with
A. Main Rotor Drive Shaft Removal holes in drive shaft.
Main rotor drive shaft is a high-
CAUTION ly stressed part. Do not allow
(3). Install three eyebolts, washers, and
nuts. Using torque wrench adapter
tools to strike shaft, or shaft to strike any (ST704), torque nuts to 120 140
object. Any impact damage may require re- inchpounds (13.56 15.82 Nm).
placement of drive shaft.
(4). With fairing support spacers and
(1). Remove main rotor fairing. special washers in place, position main
rotor fairing support so that eyebolt
(2). Remove seven externalwrenching shoulders are inserted in large holes in
bolts; and associated hardware. Lift off fairing support. Make certain that
main rotor fairing support and remove support extensions are between pitch
seven spacers. housings.
Any time drive shaft is removed, (5). Install seven externalwrench bolts,
CAUTION cover opening in top of main ro- seven washers and nuts as in step (3).
tor hub to prevent possible entry of foreign above.
matter into hub, mast and transmission.
NOTE: Phillips screws, used to attach main ro-
NOTE: If special washers between fairing sup- tor hub fairing, may be replaced with hex
port and drive shaft dome are not bonded to head Phillips screws (PN NAS1096310)
the underside of fairing support, remove and washers (PN HS306223). The hex
washers before proceeding. head will make torquing the screws easier.
(3). Remove three eyebolts and associated (6). Install main rotor fairing with five
hardware and lift drive shaft clear of screws. Torque screws to 20 25
main rotor hub. inchpounds (2.26 2.82 Nm).
Page 401
631000 Revision 20
MAINTENANCE MANUAL
HUB FAIRING
EYEBOLT (3 PLCS AS SHOWN) SCREW

(NOTE 4) (5 PLCS)
NOTE 1 WASHER
(5 PLCS)
EXTERNAL
WRENCHING BOLT
(7 PLCS)
NOTE 1
FAIRING SUPPORT
(NOTE 5)
NOTE 3
SPACER
(7 PLCS)
CORK
(NOTE 2)
DRIVE SHAFT
HUB
THIN WASHERS
(TYP, 10 PLACES)
TORQUE WRENCH
ADAPTER
369D/E/FF 500N INSTALLATION
NOTES:
1. INSTALLED WITH COUNTERSINK NEXT TO BOLT HEAD, WASHERS UNDER NUT ARE FLAT.
2. INSTALLED WITH SEALING COMPOUND.
3. MAY BE BONDED TO FAIRING SUPPORT.
4. WHEN INSTALLING EYEBOLTS, ENSURE FAIRING SUPPORT ARMS ARE NOT POSITIONED OVER
PITCH HOUSINGS.
5. THREE HOLES IN FAIRING SUPPORT ARE LARGER TO GO OVER EYEBOLTS AND TO AID IN FAIRING G631001B
SUPPORT ALIGNMENT.
Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2)
Page 402
Revision 20 631000
MAINTENANCE MANUAL
BOLT
MAIN ROTOR (9 PLACES)
DRIVE SHAFT
EYEBOLT COUNTERSUNK WASHER
(3 PLACES) (NOTE 2)
(NOTE 1)
COUNTERSUNK WASHER FLAT WASHER
(NOTE 2)
FLAT WASHER MAIN ROTOR HUB
WASHER
WASHER
NUT
NUT
600N INSTALLATION
NOTES:
1. ALIGN HOLES IN EYE BOLTS TO MATCH HOISTING ADAPTER.
2. COUNTERSINK IN WASHER TO FACE BOLT HEAD. 6G63008
Figure 401. Main Rotor Drive Shaft Installation (Sheet 2 of 2)
Page 403
631000 Revision 20
MAINTENANCE MANUAL
3. Main Transmission Drive Shaft less than 25 inchpounds (2.82

Nm) before torquing bolt.
The main transmission drive shaft is equipped
with a flexible diaphragmtype joint and (b). For 36F5450 clutch, actual drag
mounting flange (coupling) at each end. The torque plus 315 365 inch
shaft connects the overrunning clutch and the pounds (35.59 41.24 Nm). If bolt
transmission input shaft. is not seated and/or existing torque is
found to be less than 315 365
4. Main Transmission Drive Shaft inchpounds (35.59 41.24 Nm),
Replacement ensure selflocking drag torque is not
less than 25 inchpounds (2.82
(Ref. Figure 402) Nm) before torquing bolt.
Compression of drive shaft dia-
A. Main Transmission Drive Shaft Removal CAUTION phragms (static state) is limited
(Bendix and Kamatic)
to 0.020 inch (0.508 mm). Do not stress dia-
(1). Remove sound insulation and main phragms by forcing drive shaft into position
transmission access cover over main for installation in step (2). below.
transmission drive shaft in cargo NOTE: If original shaft and couplings are being
compartment. reinstalled, a check of shimming as de-
scribed below is not necessary. Install drive
(2). Remove eight bolts and washers that shaft to clutch and transmission couplings
secure shaft to couplings. as described in steps (1). above and (4). be-
low.
(3). Remove drive shaft; use care to keep it
from striking any object. (2). Position drive shaft alongside transmis-
sion input and clutch couplings. If
NOTE: Clutch oil level should be checked any compression is required to fit shaft
time engine or main drive shaft is removed between couplings, continue with step
(Ref. Sec. 120000). (3). below. If there is a gap between
drive shaft flanges and coupling
B. Main Transmission Drive Shaft flanges, continue with step (6). below.
Installation (Bendix and Kamatic)
NOTE: Removal or addition of shims should be
accomplished at transmission input cou-
pling only. Shims at overrunning clutch cou-
pling are of predetermined thickness to pre-
Item Nomenclature
vent Oring damage and oil leakage.
CM112 Antiseize compound high temperature (3). Remove coupling bolt that secures
transmission input coupling; remove
coupling and shims.
(1). Check overrunning clutch for correct oil
level, indications of oil seepage, drive CAUTION
shaft couplings for corrosion and that
coupling bolt securing clutch coupling is D The 0.010 inch (0.254 mm) minimum
torqued to: measurement between the bolt seating
surface and the input shaft must be ob-
(a). For 369A5350 clutch, actual drag tained to ensure proper clamp up. Warped
torque plus 250 300 inch shims or foreign material could provide a
pounds (28.25 33.90 Nm). If bolt false 0.010 inch (0.254 mm) minimum
is not seated and/or existing torque is measurement and improper clamp up
found to be less than 250 300 could result during normal operation
inchpounds (28.25 33.90 Nm), which may damage the main transmis-
ensure selflocking drag torque is not sion input shaft.
Page 404
Revision 36 631000
MAINTENANCE MANUAL
D Do not use clutch coupling shims under bolts to 50 70 inchpounds (5.65

transmission input coupling. Inside diam- 7.91 Nm).
eter of clutch coupling shims, 1.2601.270
inches (3.20043.2258 cm), is approxi- (7). Manually align drive shaft and trans-
mately 0.070 inch (1.778 mm) larger than mission input coupling flanges:
inside diameter of shims used at trans- (8). Using feeler gage, measure gap be-
mission coupling. Incorrect diameters can tween flanges. Gap should be 0.010
cause an improperly seated shim, mis- inch (0.254 mm) gap to 0.020 inch
alignment and cocked coupling. (0.508 mm) compression.
NOTE: Transmission input coupling shims are (a). If gap is 0.010 inch (0.254 mm) or
laminated stock. Each lamination is 0.002 less, attach upper end of drive shaft
inch (0.051 mm) thick. Peel to thickness re- to transmission input coupling with
quired. four bolts and washers. Torque bolts
(4). Add sufficient shims to get a measure- Nm).
ment of 0.010 inch (0.254 mm) mini-
mum between bolt seating surface on (b). If gap exceeds 0.010 inch (0.254 mm),
coupling and transmission input shaft. repeat step (3). thru (5). above,
except install thickness of shims
equal to measured gap, plus thick-
(5). Lubricate input shaft splines with ness that results in not more than
grease (CM111). Coat bolt threads with 0.010 inch (0.254 mm) gap between
antiseize compound (CM112). Rein- coupling and drive shaft nor more
stall coupling and bolt. Check coupling than 0.020 inch (0.508 mm) compres-
bolt for minimum drag of 25 inch sion of flexible couplings. Install four
pounds (2.82 Nm). Torque bolt to 250 bolts and washers and torque bolts to
300 inchpounds (28.25 33.90 50 70 inchpounds (5.65 7.91
Nm) plus drag torque. Nm).
(6). Attach drive shaft to clutch coupling (9). Install access door and sound insulation
with four bolts and washers. Torque over main transmission drive shaft.
TRANSMISSION INPUT COUPLING
INTERNALWRENCHING BOLT
MAIN TRANSMISSION DRIVE SHAFT
(EARLY CONFIGURATION) (BENDIX)
DIAGRAM
0.010 IN. (0.254 MM)

MAXIMUM GAP
0.020 IN. (0.508 MM)
MAXIMUM COMPRESSION
MAIN TRANSMISSION DRIVE SHAFT

DRIVE (CURRENT CONFIGURATION) (KAMATIC)
PULLEY
TRANSMISSION INPUT
COUPLINGTODRIVE SHAFT ATTACHMENT
G631002B
Figure 402. Main Transmission Drive Shaft Installation
Page 405
631000 Revision 27
MAINTENANCE MANUAL
5. Overrunning Clutch (b). Insert a long 3/8 inch (9.525 mm) hex
wrench, approximately 10 inches
The overrunning clutch transmits power from (25.4 cm) long, through tool and into
the engine to the main transmission drive back of clutch assembly.
shaft. The clutch disengages the engine from
the remainder of the drive system in case of (c). While holding internal hex wrench
engine failure and during autorotations. [3/8 inch (9.525 mm)], turn external
hex wrench [1.00 inch (2.54 cm)]
The clutch contains a sprag unit that disen- counterclockwise to remove bolt
gages automatically when N2 rpm is less than from back of clutch.
corresponding main rotor rpm.
(5). Remove nuts and washers that secure
Repair and overhaul information for the overrunning clutch; remove clutch.
overrunning clutch can be found in COM. (6). If clutch is being replaced, install spare
coupling bolt and Oring or suitable
6. Overrunning Clutch Replacement plug in output shaft (clutch inner race
bore) to prevent contamination during
(Ref. Figure 403 or Figure 404) clutch handling, shipping or storage.
A. Overrunning Clutch Removal NOTE: Operating lubricant is an approved pre-
servative for shipping or storage.
Consumable Materials (7). Wrap clutch in barrier material
(Ref. Section 910000) (CM208) to protect splined areas of
Item Nomenclature shafts.
CM208 Barrier material B. Overrunning Clutch Installation
NOTE: For removal of only the internal clutch Consumable Materials

subassembly as an alternative to complete (Ref. Section 910000)
clutch removal, refer to Overrunning Clutch Item Nomenclature
Subassembly Removal. CM111 Grease, aircraft
CM112 Antiseize compound high temperature
(1). Remove engine. CM125 Oil
(2). Remove bolts, washers, nuts and engine CM126 Oil, turbine
shaft firewall seal from clutch.
(1). If clutch is new, (369A5350 clutch only)
NOTE: Removal of clutch coupling from clutch drain preservative oil. Trapped oil can
is unnecessary unless clutch is being re- be removed by inverting clutch a
placed. minimum of three times. Add lubricat-
ing oil (CM125 or CM126) (Ref. Sec.
(3). Remove coupling bolt, packing, clutch
120000). Temporarily install coupling
coupling and coupling shim(s). Keep
bolt and packing.
shim(s) with coupling for reuse.
Reinstall bolt and packing to prevent NOTE: Relubricate splines on clutch input
spillage of lubricating oil from clutch shaft and splines inside engine power and
housing during final steps of removal. accessory gearbox with grease (CM111)
prior to reinstalling overrunning clutch.
(4). On 369F5450 clutch, remove output
shaft cover plate from back of engine (2). Coat clutch splines and internal splines
accessory drive to gain access to clutch of engine power accessory gearbox with
bolt. lubricant (CM111). Insert overrunning
clutch outerrace spline into engine and
(a). Insert tool (Ref. Figure 405) to install six washers and nuts.
engage bolt in back of clutch. Deleted.
Page 406
Revision 42 631000
MAINTENANCE MANUAL
CLUTCH
LAMINATED SHIM
GAP
0.035 IN. (0.889 MM)
0.055 IN. (1.397 MM)
MAIN DRIVE SHAFT

COUPLING OVERRUNNING
CLUTCH SHAFT
COUPLING
BOLT CLUTCH
COUPLING
COUPLINGTOCLUTCH SHIMMING
LAMINATED
COUPLING SHIM
ENGINE SHAFT
FIREWALL SEAL
ORING
OVERRUNNING
CLUTCH
REPLACEMENT OF COMPLETE CLUTCH
CLUTCH SUBASSEMBLY
RETAINING RING
(BEVELED SIDE OUTWARD) ENGINE POWER AND
ACCESSORY GEARBOX
ENGINE SHAFT
FIREWALL SEAL
REPAIR BY REPLACEMENT CLUTCH HOUSING

OF CLUTCH SUBASSEMBLY
G631003A
Figure 403. 369A5350 Overrunning Clutch Installation
Page 407
631000 Revision 20
MAINTENANCE MANUAL
369F5160
COUPLING BOLT 369F5133
COUPLING
369F54671 SEAL ASSEMBLY

3X MS5195742 SCREW
3X NAS620A8L WASHER
369F5450501
CLUTCH ASSEMBLY
369F54681 BOLT (C20 SERIES ENGINE)

369F54691 BOLT (C30/C47 ENGINE)
M83248/1019 PACKING
NOTE
M83248/2026 PACKING
0.0100.030 IN.
(0.2540.762 MM)
COUPLING SHIMMING
ROTATED
NOTE: LUBRICATE SPLINES BEFORE ASSEMBLY WITH GREASE

(CM111). PACK ALL VOIDS AND GAPS BETWEEN THE OUTSIDE
OF BOLT AND INSIDE OF ENGINE POWER OUTPUT SHAFT. CSP102013C
Figure 404. 369F5450 Overrunning Clutch Installation
Page 408
Revision 32 631000
MAINTENANCE MANUAL
(3). For 369F5450 clutch installation: (b). Shim coupling to achieve 0.0350.055
inch (0.8891.397 mm) step above
(a). Remove power output shaft cover clutch output shaft.
plate from back of engine (Ref. Sec.
010000, Allison Engine Operation When installing clutch coupling
CAUTION bolt, installation torque on the
and Maintenance Manual).
bolt must be 250 300 inchpounds (28.25
(b). Install Orings on 369F5469 33.90 Nm) for the 369A5350 clutch or 315
(C30/C47 engine) or 369F5468 (C20 365 inchpounds (35.59 41.24 Nm) for
series engines) bolt (Ref. Figure 404). the 369F5450 clutch. Torquing to lower val-
ue reduces clutch bearing clampup and can
NOTE: Fill all voids and gaps between the out- result in bearing race spinning.
side of bolt and inside of engine shaft with
grease. (6). Coat clutchtocoupling splines with
grease (CM111); install shim(s) and
(c). Lubricate internal spline area of clutch coupling. Coat coupling bolt
engine output shaft with grease threads with antiseize compound
(CM111). (CM112); install bolt with new Oring.
Check for bolt selflocking drag torque
(d). Lubricate bolt threads with anti of 25 inchpounds (2.82 Nm) mini-
seize compound (CM112) and insert mum to 200 inchpounds (22.60
through engine into overrunning Nm) maximum. Replace bolt if torque
clutch assembly. values are exceeded.
(e). Using bolt removal tool (Ref. (a). For 369A5350 clutch, torque coupling
Figure 405) either hold output bolt to actual drag torque plus 250
coupling to prevent overrunning 300 inchpounds (28.25 33.90
clutch from turning or insert hex Nm).
wrench through bolt to engage and
(b). For 36F5450 clutch, torque coupling
hold clutch.
bolt to actual drag torque plus 315
(f). Torque bolt to 250 300 inch 365 inchpounds (35.59 41.24
pounds (28.25 33.90 Nm) plus Nm).
drag torque. (7). Install engine shaft firewall seal, bolts,
washers, and nuts.
(g). Using existing hardware, reinstall
power output shaft cover plate on (8). Reinstall engine.
back of engine (Ref. Sec. 010000,
Allison Engine Operation and 7. Overrunning Clutch Subassembly
Maintenance Manual). Replacement
(4). Shim coupling on 369F5450 clutch (Ref. Figure 403 or Figure 404)
assembly as follows:
A. Overrunning Clutch Subassembly
(a). Remove output coupling bolt and Removal
coupling.
(1). Remove main transmission drive shaft.
(b). Shim coupling to achieve 0.0100.030 (2). For 369F5450 clutch installation:
inch (0.2540.762 mm) step above
clutch output shaft. (a). Remove power output shaft cover
(5). Shim coupling on 369A5350 clutch 010000, Allison Engine Operation
assembly as follows: and Maintenance Manual).
(a). Remove output coupling bolt and (b). Insert tool (Ref. Figure 405) to
coupling. engage bolt in back of clutch.
Page 409
631000 Revision 39
MAINTENANCE MANUAL
(c). Insert a long 3/8 inch (9.525 mm) hex (b). Install Orings on 369F5469
wrench, approximately 10 inches (C30/C47 engine) or 369F5468 (C20
(25.4 cm) long, through tool and into series engines) bolt (Ref. Figure 404).
back of clutch assembly.
NOTE: Fill all voids and gaps between the out-
(d). While holding internal hex wrench side of bolt and inside of engine shaft with
[3/8 inch (9.525 mm)], turn external grease.
hex wrench [1.00 inch (2.54 cm)] (c). Lubricate internal spline area of
counterclockwise to remove bolt engine output shaft with grease
from back of clutch. (CM111).
(3). Remove coupling bolt, clutch coupling (d). Lubricate bolt threads with anti
and shims. seize compound (CM112) and insert
through engine into overrunning
(4). Remove retaining ring from clutch clutch assembly.
housing. Then pull complete clutch
subassembly out of housing. (e). Using bolt removal tool (Ref.
Figure 405) either hold output
B. Overrunning Clutch Subassembly coupling to prevent overrunning
Installation clutch from turning or insert hex
wrench through bolt to engage and
Consumable Materials hold clutch.
(Ref. Section 910000) (f). Torque bolt to 250 300 inch
Item Nomenclature pounds (28.25 33.90 Nm) plus
CM111 Grease, aircraft drag torque.
CM125 Oil (g). Using existing hardware, reinstall
CM126 Oil, turbine power output shaft cover plate on
back of engine (Ref. Sec. 010000,
Allison Engine Operation and
(1). Remove shipping plug and Oring from Maintenance Manual).
end of shaft in replacement clutch
subassembly. (h). Lubricate coupling bolt threads with
antiseize compound (CM112).
(2). Drain preservative oil from clutch
subassembly by inverting it several (7). Install clutch coupling, shims and
times. Add lubricating oil (CM125 or coupling bolt.
CM126) (Ref. Sec. 120000).
(8). Install main transmission drive shaft.
(3). Coat clutch splines with grease 8. Overrunning ClutchtoFirewall Seal
(CM111).
The overrunning clutchtofirewall seal
(4). Using care to avoid oil spillage, insert consists of a stamped steel backing and a seal
clutch subassembly into clutch housing bonded to the cupped diameter of the backing.
and install retaining ring with beveled
side outward. 9. Overrunning ClutchtoFirewall Seal
Replacement
(5). Check fluid level of clutch assembly
before installing clutch coupling (Ref. (Ref. Figure 403)
Sec. 120000). (1). Remove engine.
(6). For 369F5450 clutch installation: (2). Remove three bolts, six washers and
three nuts that attach firewall seal to
(a). Remove power output shaft cover overrunning clutch.
010000, Allison Engine Operation (3). Position replacement clutchtofirewall
and Maintenance Manual). seal assembly on flange of clutch with
Page 410
Revision 32 631000
MAINTENANCE MANUAL
seam orientated at the 6 oclock position D Do not use clutch coupling shims under
and secure with attaching hardware. transmission input coupling. Inside diam-
eter of clutch coupling shims, 1.2601.270
10. Main Transmission Drive Shaft Couplings inches (3.20043.2258 cm), is approxi-
mately 0.070 inch (1.778 mm) larger than
The main transmission drive shaft couplings inside diameter of shims used at trans-
connect the overrunning clutch to the drive mission coupling. Incorrect diameters can
shaft and the drive shaft to the main transmis- cause an improperly seated shim, mis-
sion. alignment and cocked coupling.
11. Main Transmission Drive Shaft Coupling NOTE: Transmission input coupling shims are
Replacement laminated stock. Each lamination is 0.002
inch (0.051 mm) thick. Peel to thickness re-
(Ref. Figure 402) quired.
A. Main Transmission Drive Shaft Coupling (1). Install previously removed shims or
Removal refer to Main Transmission Drive Shaft
Installation for shim thickness calcula-
(1). Remove drive shaft; use care to keep it tion.
from striking any object.
(2). Lubricate drive shaft splines with
(2). Remove coupling bolt from main grease (CM111) and install in place.
transmission and overrunning clutch. Coat bolt threads with antiseize
Retain shim(s) with couplings for compound (CM112) and install.
reinstallation.
(a). For 369D25100 transmission instal-
B. Main Transmission Drive Shaft Coupling lation, torque coupling bolt to actual
Installation drag torque plus 250 300 inch
pounds (28.25 33.90 Nm). If bolt
is not seated and/or existing torque is
Consumable Materials found to be less than 250 300
(Ref. Section 910000) inchpounds (28.25 33.90 Nm),
Item Nomenclature ensure selflocking drag torque is not
CM111 Grease, aircraft less than 25 inchpounds (2.82
CM112 Antiseize compound high temperature Nm) before torquing bolt.
(b). For 369F5100 transmission installa-
tion, torque coupling bolt to actual
CAUTION drag torque plus 315 365 inch
pounds (35.59 41.24 Nm). If bolt
D The 0.010 inch (0.254 mm) minimum is not seated and/or existing torque is
measurement between the bolt seating found to be less than 315 365
surface and the input shaft must be ob- inchpounds (35.59 41.24 Nm),
tained to ensure proper clamp up. Warped ensure selflocking drag torque is not
shims or foreign material could provide a less than 25 inchpounds (2.82
false 0.010 inch (0.254 mm) minimum Nm) before torquing bolt.
measurement and improper clamp up
could result during normal operation (3). Reinstall main transmission drive
which may damage the main transmis- shaft, main transmission access cover
sion input shaft. and sound insulation.
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631000 Revision 34
MAINTENANCE MANUAL
12. Tail Rotor Drive Shaft Coupling Do not immerse Bendix flexible
Replacement CAUTION couplings in fluid or cleansers
such as magnetic particle, fluorescent pene-
A. Tail Rotor Drive Shaft Coupling Removal trant, visible dye etc. Do not apply corrosion
protection fluids unless coupling has been
cleaned with solvent or detergent. Apply
(1). Remove tail rotor drive shaft (Ref. Sec. any corrosion protection very sparingly to
631510). outside only.
NOTE: With Bendix coupling installed, remove B. Tail Rotor Drive Shaft Coupling
socket from main transmission coupling Installation
only if visual inspection reveals signs of con- According to type of coupling installed, instal-
tact between coupling bolt and socket. lation of tail rotor shaft requires shimming of
couplings, and in some instances, tail rotor
(2). Remove couplings from main and tail gearboxtotailboom shimming (Ref. Sec.
rotor transmissions. Retain shims with 631510, Tail Rotor Drive Shaft Installa-
couplings for reinstallation. tion).
Page 412
Revision 32 631000
MAINTENANCE MANUAL
0.375 IN. (9.53 MM) HEX BAR TO PICK UP 0.375 IN.

(9.53 MM) HEX SOCKET IN CLUTCH OUTER RACE
(NOTE 1)
OUTER RACE ENGINE BOLT TORQUED TO

250 300 INCHPOUNDS (28.25 33.90 NM)
1.00 IN. (2.54 CM) HEX BAR TO PICK UP

1.00 IN. (2.54 CM) HEX SOCKET IN
ENGINE BOLT (THRU HOLE IN CENTER)

0.72 IN.

(18.29 MM)
1.23 IN.

(3.124 CM)
TOOL REQUIRED
(NOTE 3)
FOR BOLT REMOVAL
0.68 IN.
(17.27 MM)
2.50 IN.
ENGINE PTO SHAFT
(6.35 CM)
(NOTE 3)
9.00 IN.
(22.86 CM)
(NOTE 3)
369F5450 CLUTCH ASSEMBLY
0.375 IN. (9.53 MM) SQUARE

0.375 IN. (9.53 MM) HEX

DRIVE EXTENSION

STANDARD 3/8" SOCKET 1.00 IN. (2.54 CM) HEX
(NOTES 2, 3)
369F5468/5469 BOLT REMOVAL TOOL
NOTES:
1. HOLD HEX BAR STEADY WHEN TORQUING BOLT.
2. TOOL TO BE A MINIMUM OF 2.5 INCHES IN LENGTH
TO CLEAR STUDS ON ENGINE.
3. THIS IS MINIMUM LENGTH, TOOL MAY BE MADE
LONGER FOR EASE OF MAINTENANCE.
G631024A
Figure 405. 369F5468/5469 Bolt Removal Tool
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631000 Revision 32
MAINTENANCE MANUAL
Page 414
Revision 32 631000
MAINTENANCE MANUAL

INSPECTION/CHECK
1. 369D25510 Main Rotor Drive Shaft (a). Thoroughly clean shaft spline with
Inspection dry cleaning solvent (CM234) to
remove oil, dirt and grease.
(Ref. Figure 601)
(b). Using magnifying glass and light,
inspect spline for cracks. Pay particu-
Consumable Materials lar attention to side of each tooth
(Ref. Section 910000) with large wear pattern (hairline
Item Nomenclature cracks appear crescentshaped
CM234 Solvent, drycleaning usually at center bottom of tooth in
root area).
(c). Inspect neck of spline (area where
spline and shaft meet) for cracks.
(1). Inspect all surfaces of drive shaft for
dents, nicks, scratches and evidence of (7). Check shaft straightness. When rotated
deformation. No damage of any kind is between centers, runout must not
permissible in the area within two exceed 0.040 inch (1.016 mm) TIR
inches of the spline. Dents less than (allowable dents excluded).
0.050 inch (1.270 mm) deep and 0.050
inch (1.270 mm) diameter are permissi- 2. 600N5510 and 369F5510 Main Rotor Drive
ble in other areas. A dent is defined as Shaft Inspection
a smooth depression of surface with no
sharp edges or abrupt changes in (Ref. Figure 601 and Figure 602)
contour. No nicks or scratches are
permitted. Consumable Materials
(2). If shaft condition is questionable, Item Nomenclature
perform magnetic particle inspection
according to Specification MILI6868. CM234 Solvent, drycleaning
No surface or subsurface defects are
permissible. Anytime main rotor drive shaft
CAUTION is removed, cover opening at top
(3). Inspect all external surfaces of shaft for of main rotor hub to prevent entry of any
corrosion. foreign material into hub, mast and trans-
mission.
(4). Remove cork plug and inspect shaft
interior for corrosion. Remove light (1). Inspect overtorque verification stripe
surface corrosion and pitting which can for straightness.
be removed without causing shaft ID to
exceed 1.655 inches (4.2037 cm). (2). Inspect all surfaces of drive shaft for
dents, nicks, scratches and evidence of
(5). Inspect splines on end of drive shaft for deformation. No damage of any kind is
excessive wear by measuring distance permissible in the area within two
across two 0.108 inch (2.7432 mm) inches of the spline. Dents less than
diameter pins placed in opposite spline 0.050 inch (1.270 mm) deep and 0.050
grooves. Dimension should be 2.2625 inch (1.270 mm) diameter are permissi-
inches (5.74675 cm) minimum. ble in other areas. A dent is defined as
a smooth depression of surface with no
(6). Inspect shaft spline for cracksusing sharp edges or abrupt changes in
bright light and 5X to 10X magnifying contour. No nicks or scratches are
glass. permitted.
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631000 Revision 26
MAINTENANCE MANUAL
1.70 IN.
(4.318 CM)
8.0 IN.
(20.32 CM)
AREA 1: MAX. PIT DEPTH 0.0012 IN. (0.03048 MM)

AREA 4: CHECK TEETH BY MEASURING ACROSS
TWO 0.108 IN. (2.7432 MM)DIAMETER PINS
PLACED IN OPPOSITE INTERTOOTH
GROOVES. MEASURED DIMENSION
SHOULD BE 2.2625 IN. (5.74675 CM) MIN.
TOOTH
0.010 IN. 0.050 IN. (1.270 MM)
CONTACT
(0.254 MM) MAX
AREA
MAX. DEPTH 5.40 IN.
13.716 CM)
0.050 IN.
(1.270 MM)
MAX
AREA 4
AREA 4
ROOT AREA
(TYP) SPLINE
NECK
LARGER WEAR SIMULATED CRACKS

NOTE: PATTERN (TYP) SHOWN
PAY PARTICULAR ATTENTION TO ROOT AREA AT EACH
SPLINE TOOTH. SIMULATED CRACKS SHOWN. ALSO
CHECK SPLINE NECK (SHADED AREA) FOR CRACKS. G631011A
Figure 601. Main Rotor Drive Shaft Inspection
Page 602
Revision 20 631000
MAINTENANCE MANUAL
(3). If shaft condition is questionable,

perform magnetic particle inspection
according to Specification MILI6868.
No surface or subsurface defects are
permissible.
(4). Inspect all external surfaces of shaft for

corrosion.
OVERTORQUE
VERIFICATION STRIPE
(5). Remove cork plug and inspect shaft
interior for corrosion. Remove light
surface corrosion and pitting which can
be removed without causing shaft ID to
exceed 1.655 inches (4.2037 cm).
(6). Inspect splines on end of drive shaft for

excessive wear by measuring distance
across two 0.108 inch (2.7432 mm)
diameter pins placed in opposite spline
grooves. Dimension should be 2.2625
inches (5.74675 cm) minimum.
(7). Inspect shaft spline for cracksusing

bright light and 5X to 10X magnifying
glass.
(a). Thoroughly clean shaft spline with 6G63003

dry cleaning solvent (CM234) to
remove oil, dirt and grease. Figure 602. Main Rotor Drive Shaft
Overtorque Verification Stripe
(b). Using magnifying glass and light,
inspect spline for cracks. Pay particu-
lar attention to side of each tooth 3. Main Transmission Drive Shaft Inspection
with large wear pattern (hairline (Bendix)
cracks appear crescentshaped
usually at center bottom of tooth in (Ref. Figure 402)
root area).
(c). Inspect neck of spline (area where Consumable Materials

spline and shaft meet) for cracks. (Ref. Section 910000)
Item Nomenclature
(8). Check shaft straightness. When rotated
between centers, runout must not CM318 Primer
exceed 0.040 inch (1.016 mm) TIR
(allowable dents excluded).
(1). Inspect drive shaft diaphragms for
(9). Apply thin coat of sealing compound dents, cracks, scratches, nicks, rust
(CM425), mixed according to container spots and evidence of joint separation
instructions, to all cork plug surfaces; from shaft or outside edges. Evidence of
press cork into drive shaft until top of any such defects on either diaphragm
cork is flush with top of drive shaft. requires removal of shaft from service.
Allow sealing compound to cure
according to container instructions. (2). Inspect drive shaft tube between
Apply second coat of sealing compound diaphragms for dents, scratches, cracks
to exposed surfaces of cork; allow to dry. or corrosion pits.
Page 603
631000 Revision 26
MAINTENANCE MANUAL
(a). Measure depth and diameter of 4. Main Transmission Drive Shaft Inspection
dents. Dents that blend smoothly into (Kamatic)
surrounding surface area with no
(Ref. Figure 402)
sharp change in contour and do not
exceed 0.015 inch (0.381 mm) depth
are acceptable. Dents not within Consumable Materials
these limits require removal of shaft (Ref. Section 910000)
from service. Item Nomenclature
CM318 Primer
(b). Measure depth of cracks, nicks,

corrosion pits, or scratches; length (1). Inspect drive shaft for dents, cracks,
and direction are not limited. Maxi- scratches, nicks, rust spots and evi-
mum depth allowed before rework is dence of joint separation from shaft or
0.003 inch (0.076 mm). outside edges.
(2). Inspect drive shaft tube between
couplings for dents, scratches, cracks or
(c). Check suspected cracks using dye
corrosion pits.
penetrant. If crack indication ap-
pears, remove black (phenolic com- (a). Measure depth and diameter of
pound) coating from area. dents. Dents that blend smoothly into
surrounding surface area with no
NOTE: Drive shaft is coated with special phe- exceed 0.010 inch (0.254 mm) in
nolic thermosetting compound. It is a brittle depth are acceptable. Dents not
coating that may indicate a crack that does within these limits require removal
not penetrate tube. of shaft from service.
(b). Measure depth of cracks, nicks,
(d). Reinspect suspected area using corrosion pits or scratches; length
magneticparticle or dyepenetrant and direction are not limited. Maxi-
methods. If crack does not reappear, mum depth allowed before rework is
touch up cleaned area with primer 0.005 inch (0.127 mm).
coating (CM318) and return part to
(c). Check suspected cracks using dye
service.
penetrant. If crack indication ap-
pears, remove coating from surface.
NOTE: Perform inspection steps (3). and (4). (d). Reinspect suspected area using
only if shaft damage is suspected. magnetic particle or dye penetrant
methods. If crack does not reappear,
touch up cleaned area with primer
(3). Inspect shaft tube for outofround
coating (CM318) and return part to
condition, which shall not exceed 0.060
service. If shaft is found to be
inch (1.524 mm).
cracked, remove shaft from service.
Kamatic parts cannot be inter-
(4). Inspect shaft for straightness. Shaft CAUTION changed between drive shafts.
shall be straight within 0.030 inch
(0.762 mm) at all locations relative to (3). Inspect all attaching hardware for
centerlines of two flange mounting bolt serviceable condition. Discard and
patterns. replace defective hardware.
NOTE: Perform the following inspections if
shaft damage is suspected.
(5). Inspect all attaching hardware for
serviceable condition. Check nut plates (4). Inspect shaft tube for outofround
for drag torque. Discard and replace condition not to exceed 0.060 inch
defective hardware. (1.524 mm).
Page 604
Revision 20 631000
MAINTENANCE MANUAL
(5). Inspect shaft for straightness. Shaft (4). Inspect socket and main transmission
shall be straight within 0.030 inch coupling bolt for signs of contact. If
(0.762 mm) at all locations relative to signs of contact are noted, remove and
centerlines of two flange mounting bolt reinstall coupling bolt and socket (Ref.
patterns. Sec. 631500). Reposition socket and
or bolt so maximum clearance between
5. Overrunning Clutch Inspection bolt key and socket is obtained.
(Ref. Figure 403 and Figure 404) Perform the 8. Kamatic Coupling Inspection
following inspections any time the helicopter
(1). Inspect coupling springs for dents,
engine or overrunning clutch assembly is
cracks, nicks and rust spots.
removed from the helicopter. For further
inspection requirements, refer to Chapter 05 (2). Inspect coupling splined section and
and Component Overhaul Manual. flange for scratches, nicks, dents,
cracks and corrosion pits. No cracks are
NOTE: Overrunning clutch subassembly can allowed. Maximum depth of other
be replaced with engine installed. defects allowed before rework is 0.005
inch (0.127 mm).
(1). Check clutch oil level (Ref. Sec.
120000). (3). Measure overall length of coupling at
three different points. If average of
(2). Remove grease and visually check readings exceed 2.630 inch (6.6802 cm),
clutch input shaft splines for wear (Ref. coupling must be replaced.
COM).
(4). Inspect drive shaft flange for signs of
NOTE: Component Overhaul Manual contains contact. If signs of contact are noted,
information relative to inspection of over- remove coupling bolt, reshim coupling
running clutch on helicopters equipped with and reinstall coupling bolt (Ref. Sec.
any cargo hook. 631500).
6. Overrunning ClutchtoFirewall Seal 9. Main Rotor Drive Shaft Inspection (300

Inspection Hour)
(Ref. Figure 601)
Inspect firewall seal and backing for cracks,
breaks, corrosion or other damage that may
prevent complete sealing of firewall opening. Consumable Materials
7. Bendix Tail Rotor Drive Shaft Coupling Item Nomenclature
Inspection CM234 Solvent, drycleaning
(1). Inspect coupling diaphragms for dents,

cracks, nicks, rust spots and joint Anytime main rotor drive shaft
CAUTION is removed, cover opening at top
separation at weld junction.
of main rotor hub to prevent entry of any
(2). Inspect coupling splined section and foreign material into hub, mast and trans-
flange for scratches, nicks, dents, mission.
cracks and corrosion pits. No cracks are
(1). Remove main rotor drive shaft (Ref.
allowed. Maximum depth of other
Main Rotor Drive Shaft Removal).
defects allowed before rework is 0.005
inch (0.127 mm). (2). Perform a visual inspection of the shaft
spline as follows:
(3). Measure overall length of couplings at
three different points. If average of (a). Thoroughly clean with cleaning
readings exceed 2.541 inches (6.45414 solvent (CM234) to remove oil, dirt,
cm), coupling must be replaced. etc.
Page 605
631000 Revision 20
MAINTENANCE MANUAL
(b). Use 5X to 10X magnifying glass and (3). Inspect all other surfaces of the drive
bright side light (45 or less; down- shaft (Ref. Main Rotor Drive Shaft
ward lighting may not define cracks). Inspection).
(c). Pay particular attention to side of NOTE: If surface corrosion or pitting of the
(each) tooth with larger wear pattern. shaft surface is noted, perform field repair of
Hairline cracks appear crescent drive shaft (Ref. Main Rotor Drive Shaft
shaped and at the center and bottom Exterior Repair and Main rotor Drive Shaft
of tooth in the root area. Also, inspect Corrosion Removal).
neck (shaded area) of spline for
cracks. (4). Remove protective cover and install
NOTE: main rotor drive shaft (Ref. Main Rotor
Drive Shaft Installation).
D If cracking is suspected, perform magnet-
ic particle inspection of shaft spline and
teeth.
D If cracking or damage is found, the shaft
is no longer airworthy. Discard drive shaft
and return it to MDHS Customer Service
Department.
D Inspect replacement drive shaft per steps
(a). thru (c). prior to installation of shaft
on helicopter.
Page 606
Revision 20 631000
MAINTENANCE MANUAL

REPAIRS
1. Main Rotor Drive Shaft Exterior Repair Exercise care when removing
CAUTION pits to ensure that shot peening
(Ref. Figure 601) No repair of drive shaft is is not completely penetrated. Remove only
permitted except for removal of light surface minimum material necessary to remove
corrosion and polishing of minor nicks and pits. Minimum wall thickness of 0.1775 inch
chips in noncritical spline areas indicated (4.5085 mm) must be maintained.
below.
(d). Lightly abrade corroded surface with
crocus cloth (CM803) to remove pits.
Consumable Materials If pit removal exceeds depth of
(Ref. Section 910000) 0.0012 inch (0.03048 mm) in Area 1
Item Nomenclature or 0.0008 inch (0.02032 mm) in Area
2, shaft is unserviceable and must be
CM121 Preservation oil replaced.
(e). Repeat steps (a). thru (c). above.
CM302 Epoxy primer / Catalyst reducer (f). Spray two coats of epoxy primer and
catalyst reducer (CM302), mixed per
CM803 Crocus cloth
manufacturers instructions, on shaft
exterior. Do not prime spline teeth or
mounting surface.
(1). Remove corrosion as follows:
(2). Polish out minor nicks and chips on
(a). Degrease corroded area of drive shaft shaft spline teeth as follows:
with clean cloth saturated with
(a). Using 320 400 grit abrasive stone,
trichloroethane (CM222).
carefully grind, blend and polish out
nicks and chips which are outside the
Surface cleaner, used in step critical (active) spline tooth contact
WARNING below, irritates hands on re-
areas (Area 4 profile and end views
peated exposure. Rubber gloves should for permissible repair areas).
be worn.
(b). If the repair (grind and polish)
(b). Swab shaft exterior with diluted operation extends beyond limits
solution of surface cleaner (CM228). shown, or if any tooth damage exists
(Mix one part surface cleaner with within the critical tooth contact area,
four parts water.) Keep wet with shaft is unserviceable and must be
solution for 10 minutes or until replaced.
corrosion appears to be removed.
(c). Perform magnetic particle inspection
Wipe clean and inspect. Repeat as
according to Specification MIL
necessary until there is no further
I6868. No surface or subsurface
evidence of corrosion.
defects are permissible.
(c). Rinse with water and dry with (3). Apply preservation oil (CM121) to
compressed air. spline teeth.
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631000 Revision 20
MAINTENANCE MANUAL
(4). Immediately reinstall main rotor drive Do not allow epoxy primer or
shaft. CAUTION epoxy enamel to contact drive-
shaft splines or mounting surfaces.
2. Main Rotor Drive Shaft Corrosion
Removal (7). Fill shaft with epoxy primer (CM302)
mixed according to manufacturers
(Ref. Figure 601) instructions. Drain primer from shaft.
Ensure that shaft ID is completely
coated. Allow primer to dry one hour at
Consumable Materials room temperature.
Item Nomenclature (8). Apply one coat of black epoxy enamel
(CM304) to driveshaft by filling and
draining shaft. Allow enamel to dry 48
CM228 Surface cleaner hours at room temperature or let dry 30
CM302 Epoxy primer / Catalyst reducer minutes at room temperature, then
CM303 Wash primer cure for three hours in oven at 250
CM304 Enamel, epoxy 275F (122 136C).
CM425 Sealing compound (9). Apply thin coat of sealing compound
(CM425), mixed according to container
instructions, to all cork plug surfaces;
(1). Degrease entire shaft inner diameter press cork into drive shafts until top of
(ID), using 1, 1, 1, trichloroethane cork is flush with top of drive shaft.
(CM222). Allow sealing compound to cure
according to container instructions.
(2). Using a fine wire rotary brush or wire Apply second coat of sealing compound
brush, remove corrosion and contami- to exposed surfaces of cork; allow to dry.
nants from drive shaft ID.
3. Main Transmission Drive Shaft Repair
Turco WO1 will irritate the (Bendix)
WARNING skin; always use rubber
gloves when handling this material. (Ref. Figure 402)
Wash skin exposed to Turco WO1,
thoroughly with water. Consumable Materials
(3). Using swab and extension rod, swab ID
Item Nomenclature
of driveshaft with Turco WO1
(CM228), diluted one part to four parts CM318 Primer
water. CM801 Abrasive paper, silicon carbide
CM803 Crocus cloth
(4). Thoroughly rinse drive shaft ID with
clear water; dry with compressed air.
(1). Repair of drive shaft diaphragms
(5). Using suitable light or borescope, (Bendix) is not permissible.
inspect shaft ID for corrosion pitting.
Remove pitting by honing locally. Shaft (2). Repair all damage that is no deeper
ID may not exceed 1.655 inches (4.2037 than 0.003 inch (0.076 mm).
cm) after honing. Blend honed area (a). Completely remove defect. Maintain
with existing surrounding area. If smooth transition into surrounding
pitting removal causes or would cause surface.
shaft ID to exceed 1.655 inches (4.2037
cm), replace shaft. (b). Use grade 400 wet or dry abrasive
paper (CM801) for preliminary
(6). Apply one coat of wash primer (CM303) finishing, and then polish with crocus
to shaft ID according to primer man- cloth (CM803). Restore surface until
ufacturers instructions. it equals original finish of shaft.
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Revision 20 631000
MAINTENANCE MANUAL
(c). After rework, check shaft tube wall Care should be taken when re-
thickness in repair area. Wall thick- CAUTION moving or installing nutplates
ness shall not be less than 0.025 inch in Kamatic drive shafts. Damage to flex
(0.635 mm). frames could cause drive shaft replacement.
(d). Apply primer coating (CM318) for (a). Carefully drill out rivets securing
corrosion protection. nutplate.
(b). Using two MS20605MP3W3 rivets,

4. Main Transmission Drive Shaft Repair install a new MS21075L4 nutplate
(Kamatic) in place.
5. Overrunning Clutch Repair/Overhaul

(Ref. Section 910000) Accomplish repair/overhaul of overrunning
Item Nomenclature clutch according to instructions in COM.
CM318 Primer
6. Overrunning ClutchtoFirewall Seal
CM801 Abrasive paper, silicon carbide Repair
CM803 Crocus cloth
(1). Repairs of Kamatic drive shaft flexible
Item Nomenclature
couplings are limited. Repairs to spring
area are not allowed. No cracks are CM411 Adhesive, epoxy
allowed.
Replace engine firewall seal by bonding new
(2). Repair drive shaft tube area damage seal to backing with adhesive (CM411).
that is no deeper than 0.005 inch (0.127
mm). Maximum depth after repair is
7. Main Transmission Drive Shaft Coupling
0.010 inch (0.254 mm). The maximum
Corrosion Removal
thickness of material removed shall not
be more than 10 percent of the original
material thickness. Consumable Materials
(a). Completely remove defect. Maintain Item Nomenclature
smooth transition into surrounding CM801 Abrasive paper, silicon carbide
surface. CM804 Emery cloth, fine
(b). Use grade 400 wet or dry abrasive

paper (CM801) for preliminary (1). Prior to installing original drive shaft
finishing, then polish with crocus coupling (369A5512 or 369H5560 only),
cloth (CM803). Restore surface until inspect flange face of coupling for
it equals original finish of shaft. corrosion. Evidence of corrosion may be
removed by hand lapping the affected
(c). After rework, check shaft tube wall parts by using a sheet of #440 (or finer)
thickness in repair area. emery cloth (CM804) or wet or dry
abrasive paper (CM801) placed on a
surface table with a figure eight motion,
(d). Apply primer coating (CM318) for using care not to let the part rock.
corrosion protection.
NOTE: Couplings may be reused if flange is not
(3). Replace nutplates on Kamatics drive less than 0.100 inch (2.540 mm) after clean-
shafts as follows: up. Recheck shimming.
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631000 Revision 20
MAINTENANCE MANUAL
8. Bendix Coupling Repair 9. Kamatic Coupling Repair
Consumable Materials Consumable Materials

(Ref. Section 910000) (Ref. Section 910000)
Item Nomenclature Item Nomenclature
CM202 Metal protector, aerosol CM318 Primer
CM318 Primer CM801 Abrasive paper, silicon carbide
CM801 Abrasive paper, silicon carbide CM803 Crocus cloth
CM803 Crocus cloth CM804 Emery cloth, fine
NOTE: If coupling is cleaned with solvent or de- (1). Repairs to coupling spring areas are not
tergent, spray a light coating of metal pro- allowed.
tector (CM202) on interior and exterior of
coupling diaphragm. Dip flange of coupling (2). Repair damage to splined section and
in liquid or spray with aerosol metal protec- flange of coupling that is no deeper
tor. Wipe away excess liquid. Metal protec- than 0.005 inch (0.127 mm). Use
tor cures in eight hours at room tempera- abrasive paper grade 320 grit or finer
ture or 15 minutes at 150F (66C). (CM801) and crocus cloth (CM803) to
completely remove and polish out
Metal protector (CM202) defect. Maximum depth after rework is
WARNING must only be used in a well
0.007 inch (0.178 mm). Apply primer
ventilated area. Persons using the met- (CM318) to repaired area.
al protector must follow all safety pre-
cautions normally used with a chlori- NOTE: Flange may be handlapped using a
nated solvent and all safety sheet of #440 emery cloth (CM804), placed
precautions on the product label. on a surface table. A figure 8 motion
should be used while lapping the coupling,
(1). Repairs to flexible web areas of dia-
using care not to let part rock.
phragms are not allowed.
(2). Repair damage to splined section and (3). Minimum flange thickness after
flange of coupling that is no deeper cleanup is 0.100 inch (2.540 mm).
than 0.005 inch (0.127 mm). Use (4). Replace nutplates on Kamatics cou-
abrasive paper (CM801) grade 400 plings as follows:
600 and crocus cloth (CM803) to
completely remove and polish out Care should be taken when re-
defect. Maximum depth after rework is CAUTION moving or installing nutplates
0.010 inch (0.254 mm). Apply primer in Kamatic couplings. Damage to flex
(CM318) to repaired area. frames could cause coupling replacement.
(3). Repair damage to outer welded portion (a). Carefully drill out rivets securing
of diaphragm halves as in step (2). nutplate.
above, except that maximum thickness
of material removed shall be not more (b). Using two MS20605MP3W3 rivets,
than 10 percent of original material install a new MS21075L4 nutplate
thickness. in place.
Page 804
Revision 20 631000
MAINTENANCE MANUAL
Section
631510
Tail Rotor Drive
Shaft (369D/E/FF)
MAINTENANCE MANUAL

MAINTENANCE MANUAL

1. Tail Rotor Drive Shaft washers, and remove drive shaft from
tail rotor transmission.
The tail rotor drive shaft connects the main
transmission and the tail rotor transmission.
The total drive shaft length is approximately B. Tail Rotor Drive Shaft Installation with
13 feet long for 369D/E and approximately 14 Bendix Couplings
feet long for 369FF. Flanges at each end of the
shaft attach to flexible joint couplings on the (Ref. Figure 401) Whenever main transmis-
transmission shafts. sion, tail rotor transmission, forward coupling
bolt and/or socket, transmission couplings or
2. Tail Rotor Drive Shaft Replacement coupling shims, tail rotor drive shaft or
tailboom assembly have been replaced, start
A. Tail Rotor Drive Shaft Removal installation with step (1). below. If none of
these components has been replaced, and only
(Ref. Figure 401, and Figure 402) installation is involved, start with step (7).
(1). Remove (or open) tail rotor drive shaft below.
access doors.
(2). Remove three bolts and washers that Consumable Materials
secure tail rotor drive shaft to output (Ref. Section 910000)
shaft coupling on main transmission. Item Nomenclature
(3). Disconnect chip detector wire from tail
rotor transmission. CM112 Antiseize compound high temperature
CM115 Grease, oscillating bearing
(4). Detach Sta. 284.00 bellcrank from tail
rotor transmission. CM311 Coating, logo white / Thinner
CM318 Primer
(5). Remove nuts and washers that attach
tail rotor transmission to tailboom.
To prevent damage to transmis- NOTE: If tail rotor drive shaft is replaced for
CAUTION sion input shaft coupling during torsional buckling, replace and discard
and after shaft removal, provide level sup- transmission output gear shaft coupling bolt
port for both transmission and tail rotor, as and socket, and tail rotor gearbox coupling
weight of these items might buckle coupling and coupling bolt.
diaphragm.
(1). Remove existing shims. Coat coupling
(6). With assistance in guiding shaft splines with grease (CM111) and
through damper, remove tail rotor, tail coupling failsafe bolt threads with
rotor transmission and tail rotor drive antiseize compound (CM112) before
shaft as an assembly. Slowly and assembly. Install coupling and tighten
carefully slide assembly aft until drive failsafe coupling bolt to 250 300
shaft clears tailboom. inchpounds (28.25 33.90 Nm) plus
drag torque. (Check coupling bolt for
Do not carry or otherwise sup-
CAUTION port transmission by use of cou-
drag torque serviceability of 25 inch
pounds (2.82 Nm) minimum, 200
pling. Use care with removal tools to pre- inchpounds (22.60 Nm) maximum.)
vent scratching of coupling diaphragms.
(7). Support assembly along its entire (2). Determine shim thickness required at
length, remove three coupling bolts and forward flexible coupling:
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631510 Revision 20
MAINTENANCE MANUAL
COUPLING
SHIMS
TAIL ROTOR DRIVE

SHAFT DAMPER
MAIN TRANSMISSION
SHAFT DAMPER OUTPUT GEARSHAFT
SLEEVE COUPLING
TAIL ROTOR
DRIVE SHAFT
FAILSAFE
COUPLING
BOLT
FAILSAFE
SOCKET
DRIVE SHAFT INSTALLATION
NOTES:
1. DO NOT LIFT TAIL ROTOR TRANSMISSION OR DRIVE SHAFT BY COUPLING. KEEP THE ASSEMBLY ALIGNED DURING REMOVAL.
2. SHIM AS REQUIRED.
3. ADD 0.005 IN. (0.127 MM) TO MEASURED GAP FOR MINIMUM SHIM THICKNESS.
4. HOLD COUPLING AT 1.370 IN. (34.798 MM) OD ONLY, TO BOTTOM COUPLING.
5. INSTALL BOLT WITH ANTISEIZE COMPOUND. MINIMUM DRAG TORQUE FOR COUPLING BOLT, 25 INCHPOUNDS (2.82 NM).
6. MINIMUM 0.010 IN. (0.254 MM) STEP BETWEEN AFT END OF OUTPUT SHAFT AND SHOULDER OF FORWARD COUPLING.
7. INSTALL WITH GAP EITHER SIDE OF FAILSAFE BOLT. G6310051B
Figure 401. Tail Rotor Drive Shaft Installation (369D/E/FF) (Sheet 1 of 3)
Page 402
Revision 42 631510
MAINTENANCE MANUAL
LOCK RING
AND STUD
(4 PLCS)
TRANSMISSION
COUPLING (NOTE 1)
COUPLING SHIM
TAIL BOOM
(NOTE 2)
COUPLING
BOLT
FAILSAFE
SOCKET
FAILSAFE
INPUT COUPLING BOLT
SHAFT
TAIL ROTOR TRANSMISSION TRANSMISSION

COUPLING SHIM COUPLING (NOTE 1)
(NOTE 2)
MEASURED GAP
0.0100.020 IN. THIN WASHER
ALIGNMENT
(0.2540.508 MM) (3 PLCS) AFT
1.370 IN. BOLT OR PIN
COUPLING TAIL ROTOR
(34.798 MM) OD
GEARSHAFT
(NOTE 4)
INPUT SHAFT
NOTE 3
SHIMS
MAIN TRANSMISSION
COUPLING BOLT
OUTPUT PINION
TAIL ROTOR (NOTE 5)
DRIVE SHAFT
COUPLING BOLT AFT KAMATIC COUPLING
FORWARD KAMATIC COUPLING
(NOTE 5)
0.010 IN. (0.254 MM)

MINIMUM STEP
(NOTE 6)
KAMATIC COUPLINGS
G6310052A
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631510 Revision 42
MAINTENANCE MANUAL
MEASURED GAP
0.0100.020 IN.
(0.2540.508 MM)
ALIGNMENT THIN
BOLT OR PIN D WASHER
WASHER TAIL ROTOR GEARBOX
MAIN TRANSMISSION (3 PLCS) (3 PLCS) D OUTPUT SHAFT
OUTPUT PINION
FAILSAFE
TAIL ROTOR BOLT
DRIVE SHAFT
AFT
NOTE 3 COUPLING
SHIMS 1.370 IN SHIMS

(34.798 MM) OD
(NOTE 5) FAILSAFE SOCKET
FAILSAFE BOLT D
(NOTE 5) D
FORWARD BENDIX COUPLING AFT BENDIX COUPLING
COUPLING
0.010 IN. (0.254 MM)

MINIMUM STEP FAILSAFE BOLT
(NOTE 6) FAILSAFE SOCKET (NOTE 7)
DD FAILSAFE INSTALLATION
G6310053D
Page 404
Revision 42 631510
MAINTENANCE MANUAL
(a). Install minimum shim thickness on

main transmission output shaft. CAUTION
D Ensure security of tail rotor gearbox
Bottom the flexible coupling by
CAUTION holding at the 1.370 inch
mount studs. Maximum allowable side
play at end of stud is 0.004 inch (0.102
(3.4798 cm) OD of coupling. Do not bottom
mm), maximum allowable axial play is
coupling by pushing on drive shaft attach
0.005 inch (0.127 mm) (Ref. Sec.
flange; doing so may damage coupling.
632510).
(b). Bottom forward coupling on main D When installing tail rotor transmission
transmission output shaft. and drive shaft, do not compress the for-
ward or aft couplings as damage to the
(c). Measure step between aft end of coupling could result.
output shaft and shoulder of flexible
coupling, by bottoming coupling (7). With assistance, support transmission
against shims (refer to CAUTION and shaft in line, for minimum deflec-
above). tion of coupling, and guide drive shaft
carefully through tailboom and damper
NOTE: Maintain minimum 0.010 inch (0.254 into position.
mm) step between aft end of output shaft
and coupling shoulder to prevent coupling (8). Secure transmission to four tailboom
bolt from bottoming on output shaft. mounting studs (Ref. Sec. 632510).
Install four washers and nuts, torque
(d). Install additional shims to maintain nuts to 75 95 inchpounds (8.47
0.010 inch (0.254 mm) minimum step 10.73 Nm) plus drag torque.
as required. (9). Align forward end of drive shaft with
(3). Position failsafe socket on aft face of coupling on main transmission output
forward coupling so that three of the gearshaft. Partially install two bolts as
nine holes are indexed to the three an alignment aid but do not tighten.
nutplates of the coupling in such a way Align drive shaft inspection markings.
that maximum clearance is obtained If any of four white stripes is indistinct
between the bolt key and socket. or does not exist, paint (CM311)
Visually verify proper clearance before replacement stripe:
installing tail rotor drive shaft. (10). Obtain 0.0100.020 inch (0.2540.508
mm) gap between forward flange of tail
(4). Repeat previous step to install failsafe rotor drive shaft and aft end of socket,
socket on input coupling of tail rotor using the following procedure:
transmission.
(a). Back off three attach bolts on for-
(5). Support entire length of tail rotor drive ward flange of tail rotor drive shaft
shaft and position end stamped AFT to assembly 0.0500.100 inch
align with tail rotor transmission (1.2702.540 mm).
coupling.
(b). Pull and hold tail rotor output shaft
(6). Install three bolts and washers to of main rotor transmission aft (out of
connect tail rotor transmission coupling transmission) to remove end play. If
to shaft; torque bolts to 80 100 rotor brake is installed, make certain
inchpounds (9.04 11.30 Nm) plus that brake pucks do not restrict axial
drag torque. travel of tail rotor output shaft.
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631510 Revision 43
MAINTENANCE MANUAL
(c). Remove end play in tail rotor trans- (12). With assistance, support transmission
mission by applying force to tail rotor and shaft in line for minimum deflec-
blades in opposite direction of tion of coupling and guide drive shaft
operational rotation (while holding carefully through tailboom and damper
forward coupling of tail rotor drive- into position.
shaft on main transmission output
shaft to prevent rotation). Do not (13). Apply primer (CM318) to the four
push tail rotor drive shaft fore or aft. gearbox mounting studs. Install nuts
and washers while the primer is still
(d). Using feeler gage, measure gap wet; torque evenly to 75 95 inch
between socket and flange of tail pounds (8.47 10.73 Nm) plus drag
rotor drive shaft. Socket flange must torque.
be in full contact with flange of
flexible coupling. Verify that a minimum of (1) one
CAUTION thread protrudes through each
(e). With assistance, remove tail rotor nut from the four tail rotor transmission
transmission and driveshaft in line mounting studs. If less than one thread is
for minimum deflection of coupling. showing, refer to CSPDEF6, Structural
Repair Manual, to replace with a longer
MS1992A80314 stud and insert.
(f). Using measured gap from step (d).
above, add or remove required
number of shims at tail rotor trans- (14). Install three bolts and washers at
mission input pinion shaft and forward end of tail rotor drive shaft to
coupling to obtain specified gap of connect to forward coupling; torque
0.0100.020 inch (0.2540.508 mm). bolts to 80 100 inchpounds (9.04
NOTE:
(15). Connect electrical wire to tail rotor
D Maintain minimum 0.010 inch (0.254 transmission chip detector. Torque nut
mm) step between coupling shoulder and to 12 15 inchpounds (1.36 1.69
output shaft (Ref. step (2).). Nm).
D If less than specified gap, 0.0100.020 (16). Coat pin of Sta. 284.00 bellcrank with
inch (0.2540.508 mm) exists under mini- grease (CM111) and insert it into
mum shim requirements, install a maxi- bearing in tail rotor pitch control. Pivot
mum of one HS306326 or HS306326H bellcrank to align with mating hole in
washer on each of the four tail rotor tail rotor transmission and install bolt,
transmission mounting studs, between washers, nut and cotter pin.
gearbox housing and boom fitting. Apply
primer (CM318) to both sides of washer at
installation. After washer installation, re- (17). Check transmission oil level and service
peat step (10). as required.
(11). Coat forward coupling splines with (18). Slowly rotate drive shaft and visually
grease (CM111) and coupling bolt check to ensure shaft is not bent and for
threads with antiseize compound (36) not less than 0.250 inch (6.35 mm)
before assembly. Install coupling and clearance between shaft and fairing
torque failsafe bolt to 250 300 tube at Sta. 137.5. In addition, check
inchpounds (28.25 33.90 Nm) plus for minimum clearance of 0.190 inch
drag torque. (Check coupling bolt for (4.83 mm) between shaft and cooling
drag torque serviceability of 25 inch blower scroll.
pounds minimum (2.82 Nm), 200
inchpounds (22.60 Nm) maximum.) (19). Install all access doors and covers.
Page 406
Revision 42 631510
MAINTENANCE MANUAL
COUPLING SHIMS
MAIN TRANSMISSION OUTPUT

GEARSHAFT COUPLING
TAIL ROTOR
DRIVE SHAFT
TAIL ROTOR DRIVE

SHAFT DAMPER
TAIL ROTOR DRIVE
SHAFT DAMPER SLEEVE SHAFT DAMPER
(2 PLCS)
LOCK RING AND STUD

DRIVE SHAFT INSTALLATION
(4 PLCS)
COUPLING SHIM TAILBOOM

(NOTE)
EXTENSION
COUPLING BOLT
TRANSMISSION COUPLING
INPUT SHAFT
NOTE:
SHIM AS REQUIRED. G631006
Figure 402. Tail Rotor Drive Shaft Installation (369FF)
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631510 Revision 42
MAINTENANCE MANUAL
C. Tail Rotor Drive Shaft Installation with coupling onto main transmission;
Kamatic Couplings torque coupling bolt to 250 300
inchpounds (28.25 33.90 Nm) plus
(Ref. Figure 401 and Figure 402) Whenever drag torque. (Check coupling bolt for
main transmission, tail rotor transmission, drag torque serviceability of 25 inch
transmission couplings, coupling shims, tail pounds (2.82 Nm) minimum, 200
rotor drive shaft or tailboom assembly have inchpounds (22.60 Nm) maximum.)
been replaced, start installation with step (1).
below. If none of these components have been (3). Support entire length of tail rotor drive
replaced, and only installation is involved, shaft and position end marked AFT to
start with step (5). below. align with tail rotor transmission
coupling.
Consumable Materials (4). Install three bolts and washers to
(Ref. Section 910000) connect tail rotor gearbox coupling to
Item Nomenclature shaft; torque bolts to 80 100 inch
CM111 Grease, aircraft pounds (9.04 11.30 Nm) plus drag
CM112 Antiseize compound high temperature torque.
CM115 Grease, oscillating bearing Ensure security of tail rotor
CM311 Coating, logo white / Thinner CAUTION gearbox mount studs. Maxi-
CM318 Primer mum allowable side play at end of stud is
0.004 inch (0.102 mm), maximum allowable
axial play is 0.005 inch (0.127 mm) (Ref. Sec.
NOTE: 632510).
D Kamatic couplings do not require failsafe
(5). With assistance, support tail rotor
bolts or sockets.
transmission and shaft in line, for
D When installing 369D255013 Kamatic minimum deflection of coupling, and
coupling, install SKCP255413 coupling guide drive shaft carefully through
bolt supplied with the Kamatic coupling. tailboom and damper into position.
D If tail rotor drive shaft is replaced for tor- (6). Secure transmission to four tailboom
sional buckling, replace and discard main mounting studs with washers and nuts;
transmission output gear shaft coupling, torque to 75 95 inchpounds (8.47
tail rotor gearbox coupling and both cou- 10.73 Nm) plus drag torque.
pling bolts.
(7). Align forward end of driveshaft with
(1). Coat coupling splines with grease coupling on main transmission output
(CM111) and coupling bolt threads with gearshaft. Partially install two bolts as
antiseize compound (CM112) before an alignment aid but do not tighten.
assembly. Install coupling onto tail Align drive shaft inspection markings.
rotor gearbox and torque coupling bolt If any of four white stripes is indistinct
to 250 300 inchpounds (28.25 or does not exist, paint replacement
33.90 Nm) plus drag torque (Check stripes.
coupling bolt for drag torque service-
ability of 25 inchpounds (2.82 Nm) (8). Obtain 0.0100.020 inch (0.2540.508
minimum, 200 inchpounds (22.60 Nm) mm) gap between forward flange of tail
maximum.) rotor drive shaft and flange of forward
coupling using the following procedure:
(2). Coat forward coupling splines with
grease (CM111) and coupling bolt (a). Ensure alignment bolts in previous
threads with antiseize compound step are backed off between
(CM112) before assembly. Install 0.0500.100 inch (1.2702.540 mm).
Page 408
Revision 20 631510
MAINTENANCE MANUAL
(b). Pull and hold tail rotor output shaft guide drive shaft carefully through
of main rotor transmission aft (out of tailboom and damper into position.
transmission) to remove end play. If
rotor brake is installed, ensure that (11). Secure transmission to four tailboom
brake pucks do not restrict axial mounting studs with washers and nuts;
travel of tail rotor output shaft. torque to 75 95 inchpounds (8.47
(c). Remove end play in tail rotor trans-
(12). Install three bolts and washers at
mission by applying force to tail rotor
forward coupling; torque bolts to 80
blades in opposite direction of
operation (while holding forward
plus drag torque.
coupling of tail rotor drive shaft on
main transmission to prevent rota- (13). Connect electrical wire to tail rotor
tion). Do not push tail rotor drive transmission chip detector. Torque nut
shaft fore or aft. to 12 15 inchpounds (1.36 1.69
Nm).
(d). Using feeler gage, measure gap
between forward coupling flange and (14). Coat pin of Sta. 284.00 bellcrank with
flange of tail rotor drive shaft. Record grease (CM111) and insert into bearing
the gap. in tail rotor pitch control. Pivot bell-
crank to align with mating hole in tail
(e). With assistance, remove tail rotor rotor transmission and install bolt,
transmission and driveshaft in line washers, nut and cotter pin.
for minimum deflection of coupling.
(15). Check transmission oil level and service
(f). Using measured gap from step (d). as required (Ref. Sec. 121000).
above, add or remove required (16). Slowly rotate driveshaft and check for
number of shims at tail rotor trans- not less than 0.25 inch (6.35 mm)
mission input pinion shaft and clearance between shaft and fairing
coupling to obtain specified gap of tube at Sta. 137.50. In addition, check
0.0100.020 inch (0.2540.508 mm). for minimum clearance of 0.190 inch
(4.83 mm) between shaft and cooling
NOTE: blower scroll.
D Maintain minimum 0.010 inch (0.254
mm) step between coupling shoulder and (17). Install all access doors and covers.
output shaft (Ref. Figure 401).
3. Tail Rotor Drive Shaft Damper
D If less than specified gap, 0.0100.020
inch (0.2540.508 mm) exists under mini- (Ref. Figure 603) The tail rotor drive shaft
mum shim requirements, install a maxi- damper is a graphitefilled teflon plate that
mum of one HS306326 or HS306326H controls and limits deflection of the tail rotor
washer on each of the four tail rotor drive shaft about its approximate midpoint.
transmission mounting studs, between The damper is springloaded against a
gearbox housing and boom fitting. Apply structural support bracket mounted on the aft
primer (CM318) to both sides of washer at section tailboom fairing. On 369FF Model
installation. After washer installation, re- helicopters, a second damper is located at Sta.
peat step (10). 137.50 (Ref. Figure 602).
(9). Reinstall coupling and torque coupling 4. Tail Rotor Drive Shaft Damper
bolt to 250 300 inchpounds (28.25 Replacement
(Ref. Figure 602)
(10). With assistance, support tail rotor (1). Remove boombolts access covers.
transmission and shaft in line for
minimum deflection of coupling and (2). Remove tail rotor drive shaft.
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631510 Revision 43
MAINTENANCE MANUAL
(3). Remove two bolts, washers, springs, (6). Install tail rotor drive shaft.
thin washers, plate and spacers and
damper.
(7). Displace damper so that it touches tail
NOTE: The damper at Sta. 137.50 (369FF only) rotor drive shaft.
has 369DSK15213 bushings installed in-
side the Teflon Graphite Damper in conjunc-
tion with the spacers.
(8). Use wire gage to measure damper to
(4). Position new damper over mounting shaft clearance 180 from contact point.
holes in support bracket. Install plate Minimum acceptable clearance is 0.020
and spacers with bolts, washers, inch (0.508 mm).
springs and spacer washers.
Ensure washers under bol-
CAUTION theads are seated against
(9). Repeat steps (7). and (8). above at 90
spacer when tightened. Bolts wear rapidly if intervals from initial check point.
clampup is not solid.
(5). Adjust damper friction. (10). Install boombolts access covers.
Page 410
Revision 28 631510
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Tail Rotor Drive Shaft Inspection straightness. When rotated between
centers, or with ends plugged and rolled
Inspect shaft as described below. Replace bent over roller, runout of large diameter
shaft. Other damage (scratches, nicks, etc) must not exceed 0.060 inch (1.524 mm)
that exceeds repairable limits also requires (allowable dents excluded).
shaft replacement.
(1). Inspect for scratches in shaft section 2. Tail Rotor Drive Shaft Twist Inspection
that passes through plenum chamber (Ref. Figure 601 and Figure 602) Following
fairing tube. Such scratches indicate inspection determines if drive shaft has been
possible contact with tube edges at torsionally strained to extent that permanent
bulkhead openings. twist exists.
(2). Inspect for evidence of torsional (1). Handturn main rotor until two white
buckling or shaft bending as result of stripes (A, Figure 601) are aligned.
blade strike or hard ground contact by
lower stabilizer. (2). Look inboard from tail rotor side of
helicopter and locate two white stripes
(3). Inspect for corrosion. (B, Figure 601). Stripe on input shaft
(4). Inspect for evidence of shaft damper bearing retainer flange of tail rotor
sleeve bond failure (sleeve shifting) transmission is located at approximate-
from excessive heat or loads. ly 2 oclock, looking aft. Stripe on
coupling should be at approximately 10
(5). If there is abnormal shaft vibrations, oclock, looking forward. Both stripes
check damper friction and shaft should be aligned.
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631510 Revision 20
MAINTENANCE MANUAL
TAIL ROTOR
DRIVE SHAFT
DOUBLER
TAIL ROTOR
TRANSMISSION
WHITE STRIPES
1/8 IN. (3.175 MM) WIDE STA. 137.50 RING
STA. 137.50
(LOOKING FORWARD)
DAMPER
TAIL ROTOR
DRIVE SHAFT
STA. 137.50
INPUT SHAFT TAIL ROTOR

BEARING RETAINER TRANSMISSION
WHITE STRIPES
1/8 INCH (3.175 MM)
COUPLING
WIDE
WHITE STRIPES
1/8 IN. (3.175 MM) WIDE
(EARLY CONFIGURATION)
COUPLING
AFT COUPLING
(NEW CONFIGURATION)
G631007A
Figure 601. Tail Rotor Drive Shaft Inspection Markings
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Revision 20 631510
MAINTENANCE MANUAL
TAIL ROTOR
DRIVE SHAFT
DAMPER
WHITE STRIPE
1/8 IN. (3.175 MM) WIDE
TAIL BOOM EXTENSION
INPUT SHAFT
BEARING RETAINER
COUPLING
WHITE STRIPE (1/8
INCH WIDE)
DOUBLER
BUSHING
WHITE STRIPE
1/8 IN. (3.175 MM)
WIDE
(EARLY CONFIGURATION)
WHITE
STRIPE
1/8 IN.
(3.175 MM) TAIL ROTOR
WIDE DRIVE SHAFT
STA. 137.50 RING COUPLING
(CURRENT CONFIGURATION)
STA. 137.50
(LOOKING FORWARD)
AFT COUPLING
G631008B
Figure 602. Tail Rotor Drive Shaft Inspection Markings (Extended Tailboom)
Page 603
631510 Revision 20
MAINTENANCE MANUAL
3. Tail Rotor Drive Shaft Damper Inspection NOTE: Tail rotor drive shaft must be removed
to perform following inspection.
(Ref. Figure 603)
(2). Inspect damper for correct drag friction
NOTE: If there is excessive drive shaft vibra- adjustment.
tion as shaft passes through first critical
rpm range, probable cause is defective or (3). Inspect inside diameter of damper for
loose damper. excessive wear. If diameter is more
than 3.035 inches (7.7089 cm), damper
(1). Inspect damper for shaft clearance as must be replaced.
follows:
(4). Adjust friction damper as necessary to
(a). Remove boombolts access cover.
achieve the required drag as follows:
(b). Inspect tail rotor drive shaft damper
(a). Fabricate frictionchecking tool.
and support structure for broken,
cracked or bent parts. (b). Using 010 pound spring scale,
(c). Displace damper so that it touches measure force required to move
tail rotor drive shaft. damper radially on bulkhead. Fric-
tion must be adjusted so that pull of
(d). Use wire gage to measure damper to 2 0.25 pounds (0.91 0.11 kg) is
shaft clearance 180 from contact required to slide damper between
point. Minimum acceptable clearance plate and support bracket.
is 0.020 inch (0.508 mm).
NOTE: Minimum of one washer must always
(e). Repeat steps (c). and (d). above at 90 remain between each spring and plate.
intervals from initial check point.
(c). To increase friction, add thin washers
(f). Dampers not meeting minimum between springs and plate. To
clearance of 0.020 inch (0.508 mm) at decrease friction, remove washers.
four equidistant points are to be (Add or remove same number of
replaced. washers at each spring.)
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Revision 37 631510
MAINTENANCE MANUAL
STA. 197.78
THIN WASHER
(AS REQUIRED)
WASHER
TEFLON GRAPHITE
DAMPER
BOLT
SPRING
METAL PLATE
1.13 IN.
(2.8702 CM)
BRACKET
SPACER
5.00 IN.
(12.7 CM)
SPRING SCALE
010 POUNDS
05 KG)
1.75 IN.
(4.445 CM) 2.00 IN.
2.88 IN. (5.08 CM)
(7.3152 CM)
FRICTION CHECKING TOOL

(NOTE)
NOTE:
MANUFACTURED LOCALLY FROM 1/8 IN. (3.175 MM)
CORROSION RESISTANCE SPRING WIRE. G631009A
Figure 603. Tail Rotor Drive Shaft Damper Inspection

631510 Revision 20
MAINTENANCE MANUAL

REPAIRS
1. Tail Rotor Drive Shaft Repair Procedure depth of a dent is 0.040 inch (1.016
mm). Dents that raise material require
that shaft be replaced.
2. Tail Rotor Drive Shaft Index Stripe
Item Nomenclature
Application
CM318 Primer (Ref. Figure 601 and Figure 602)
CM803 Crocus cloth Consumable Materials
Item Nomenclature
Nicks and scratches no deeper than 0.0015
CM311 Coating, logo white / Thinner
inch (0.0381 mm) are allowable without
rework but require finish protection with
chemical film (CM206). Other surface damage If any of the four white index stripes used for
shall be evaluated and repaired according to twist inspection of tail rotor drive shaft are
limits specified below. Use grade 400 abrasive indistinct or do not exist, paint (CM311)
paper (CM801) to smooth out and blend repair replacement aligning index stripes as follows:
area into surrounding material until damage
is completely removed; then polish with crocus To prevent damage to gearbox
cloth (CM803) to equal original finish. Apply CAUTION coupling during and after shaft
finish protection with chemical film and two removal, provide good level support for both
coats of primer (CM318). tail rotor transmission and shaft, as the
weight of these items might buckle the cou-
Any section of shaft that ap- pling.
CAUTION pears to be scratched, nicked or
corroded in a previously reworked area NOTE: Any time the associated tail rotor drive
must not be repaired a second time. Remove shaft units are removed or replaced, an in-
such shaft from further service. Replace any dexing check and reapplication of index
shaft that has damage in excess of following marks is required.
limits.
(1). Remove tail rotor transmission and
(1). Scratches 0.007 inch (0.178 mm) deep drive shaft as an assembly.
to maximum length of 1.00 inch (2.54
cm) at any random angle may be (2). Inspect tail rotor drive shaft for
repaired. evidence of torsional twist or buckling.
(2). Scratches 0.010 inch (0.254 mm) deep (3). Remove any old index stripes.
to maximum length of 0.250 inch (6.35
mm) at any random angle may be (4). Apply white index stripe 0.120 inch
repaired. (3.048 mm) wide and 0.250 inch (6.35
mm) long onto tail rotor transmission
(3). Circumferential scratches 0.004 inch input shaft bearing flange, at approxi-
(0.102 mm) deep may be repaired. mate 10 oclock position (viewed looking
forward), so it can be seen when viewed
(4). Smoothly contoured dents are allowable on left side of tailboom.
when ratio of dent diameter to dent
depth is at least 15:1; for example, (5). Apply white index stripe 0.120 inch
when depth is 0.040 inch (1.016 mm) (3.048 mm) wide and any length, on the
minimum acceptable diameter is 0.60 aft coupling in line with index stripe on
inch (15.24 mm). Maximum acceptable tail rotor gearbox retainer.
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631510 Revision 20
MAINTENANCE MANUAL
(6). Install tail rotor drive shaft. mm) long on boom bulkhead doubler
(Sta. 137.50), at approximately 6 8
(7). Align index stripes on tail rotor gearbox oclock position looking forward.
bearing retainer and aft coupling.
(8). Remove tail rotor bellcrank access door (10). Apply a corresponding joining index
at the forward left side of fuselage boom stripe on the tail rotor drive shaft at
fairing and observe the area where tail Sta. 137.50, approximately 0.120 inch
rotor drive shaft passes through the (3.048 mm) wide and 0.50 inch (12.70
fairing forward bulkhead. mm) long.
(9). Apply white index stripe 0.120 inch
(3.048 mm) wide and 0.50 inch (12.70 (11). Install all access doors and covers.
Page 802
Revision 20 631510
MAINTENANCE MANUAL
Section
631530
NOTAR
AntiTorque System
Drive Shafts
(500/600N)
MAINTENANCE MANUAL

MAINTENANCE MANUAL
NOTAR) ANTITORQUE SYSTEM DRIVE SHAFTS

1. AntiTorque System Drive Shafts coupling and remove three bolts and
washers that secure fan gearbox drive
The Fan Gearbox Drive Shaft connects the shaft to input shaft coupling on fan
main transmission and the fan gearbox. The transmission gearbox. Support drive
total drive shaft length is approximately 14 shaft and output shaft coupling on
inches long. Flanges on each end of the shaft main transmission.
attach to flexible (Kamatic) type joint coupling
on the main transmission output shaft and fan (6). Remove fan gearbox (Ref. Sec.
gearbox input shaft. 632530).
The Fan InterConnecting Drive Shaft is (7). Remove fan gearbox drive shaft by
equipped with a kamatic flexibletype joint removing three bolts and washers from
and mounting flange (coupling) at each end. output shaft couping on main transmis-
The shaft connects the fan gearbox to the fan sion.
assembly by (two) couplings mounted on the
B. Fan Gearbox Drive Shaft Installation
output shaft of the fan gearbox and input shaft
of the fan assembly. The fan pitch control rod (Ref. Figure 201) Whenever main transmis-
is routed through the center of the intercon- sion, fan gearbox, transmission couplings,
nect drive shaft. coupling shims, fan gearbox drive shaft
assembly have been replaced, start installation
2. Fan Gearbox Drive Shaft Replacement with step (1). below. If none of these compo-
nents have been replaced, and only installa-
A. Fan Gearbox Drive Shaft Removal tion is involved, start with step (3). below.
(Ref. Figure 201)
(1). Remove fan gearbox drive shaft access (Ref. Section 910000)
doors and covers, upper aft section Item Nomenclature
fuselage and interior trim panels as
required. CM111 Grease, aircraft
(2). Remove tailboom fairing and tailboom CM115 Grease, oscillating bearing
(Ref. Sec. 534030). CM318 Primer
(3). Remove fan pitch control rod (Ref. Sec.
672030). NOTE: Kamatic couplings do not require fail-
(4). Remove fan interconnecting drive safe bolts or sockets. When installing
shaft (Ref. Fan InterConnect Drive 369D255019 Kamatic coupling, install
Shaft Replacement). SKCP255415 coupling bolt supplied with
the Kamatic coupling or 369D255031 bolt.
If fan gearbox drive shaft is replaced for
WARNING torsional buckling, replace and discard
main transmission output gear shaft
D To prevent damage to the engine in- coupling, fan gearbox coupling and both
stall F.O.D. cover over engine air in- coupling bolts.
let.
D To prevent damage to shaft provide (1). Coat coupling splines with grease
level support for fan transmission (CM111) and coupling bolt threads with
drive shaft during removal or instal- antiseize compound (CM112) before
lation. assembly. Install coupling onto fan
gearbox input shaft and torque coupling
(5). Gain access thru plenum chamber and bolt to 250 300 inchpounds (28.25
remove drive shaft access panel to aft 33.90 Nm) plus drag torque. Check
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631530 Revision 20
MAINTENANCE MANUAL
coupling bolt for drag torque service- (b). Pull and hold fan output pinion shaft
ability of 25 inchpounds (2.82 Nm) of main rotor transmission aft (out of
minimum, 200 inchpounds (22.60 Nm) transmission) to remove end play. If
maximum. rotor brake is installed, ensure that
brake pucks do not restrict axial
travel of fan output shaft.
(2). Coat forward coupling splines with
grease (CM111) and coupling bolt (c). Remove end play in fan transmission
threads with antiseize compound by applying force to the coupling in
(CM112) before assembly. Install opposite direction of operation while
coupling onto main transmission output still holding forward coupling of drive
shaft and torque coupling bolt to 250 shaft on main transmission. Do not
300 inchpounds (28.25 33.90 Nm) push fan drive shaft fwd or aft.
plus drag torque. Check coupling bolt
for drag torque serviceability of 25 (d). Using feeler gage, measure gap
inchpounds (2.82 Nm) minimum, 200 between forward coupling flange and
inchpounds (22.60 Nm) maximum. flange of fan drive shaft using
average of 3 readings. Record the
gap.
(3). Support drive shaft and position to
align with fan transmission coupling on (e). Adjust the number of shims
main transmission. (369A55163, 5, 7, or 9). Using
measured gap from step 4 above, add
(4). Install fan gearbox with four mounting or remove required number of shims
bolts and torque to 70 90 inch behind the coupling of main trans-
pounds (7.90 10.17 Nm); torque mission output pinion shaft or
stripe bolts. between fan gearbox forward cou-
pling to obtain specified gap of
0.0100.020 inch (0.2540.508 mm).
NOTE: If reshimming is required, removal
and installation of the fan gearbox is neces- NOTE: All shims may be removed from forward
sary to obtain the specified gap between the or aft coupling if required.
coupling flange and flange of drive shaft.
(f). Coat forward coupling splines with
grease (CM111) and coupling bolt
(5). Install three bolts and washers to threads with antiseize compound
connect fan gearbox coupling to drive (CM112) before assembly. Install
shaft; torque bolts to 80 100 inch coupling and torque coupling bolt to
pounds (9.04 11.30 Nm) plus drag 250 300 inchpounds (28.25
torque. 33.90 Nm) plus drag torque. Check
coupling bolt for drag torque service-
(6). Align forward end of drive shaft with ability of 25 inchpounds (2.82 Nm)
coupling on main transmission output minimum, 200 inchpounds (22.60
gearshaft. Partially install three bolts Nm) maximum.
as an alignment aid but do not tighten. (8). Install three bolts and washers at
forward coupling; torque bolts to 80
(7). Obtain 0.0100.020 inch (0.2540.508 100 inchpounds (9.04 11.30 Nm)
mm) gap between forward flange of the plus drag torque.
fan gearbox drive shaft and flange of
(9). Slowly rotate drive shaft and check for
forward coupling using the following
not less than 0.25 inch (6.35 mm)
procedure:
clearance between shaft and fairing
tube at Sta. 137.50. In addition, check
(a). Ensure alignment bolts in previous for minimum clearance of 0.190 inch
step are backed off between (4.83 mm) between shaft and cooling
0.0500.100 inch (1.2702.540 mm). blower scroll.
Page 202
Revision 43 631530
MAINTENANCE MANUAL
(10). Install fan gearbox (Ref. Sec. (1). Replace bent shaft. Other damage
632530). (scratches, nicks, etc.) that exceeds
repairable limits also requires shaft
(11). Install interconnecting drive shaft replacement.
(Ref. Fan InterConnect Drive Shaft
Replacement) (2). Inspect for scratches in shaft section
that passes through plenum chamber
(12). Install fan pitch control; control rod fairing tube. Such scratches indicate
(Ref. Sec. 672030). possible contact with tube edges at
bulkhead openings.
(13). Install tailboom and fairing (Ref. Sec.
534030). (3). Inspect for evidence of torsional twist,
buckling or shaft bending as result of
(14). Check antitorque flight control rigging blade strike or hard ground contact.
(Ref. Sec. 672030). (4). Inspect for corrosion.
(15). Install all access doors and covers, and 4. Fan Gearbox Drive Shaft Repair
interior trim panels. Procedure
3. Fan Gearbox Drive Shaft Inspection For information on repair procedures, refer to
Sec 631510, Tail Rotor Drive Shafts Repair
Inspect shaft as described below. Procedure.
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631530 Revision 20
MAINTENANCE MANUAL
BOLT
(NOTE 3)
SHIM
SHAFT
COUPLING
BOLT
(NOTE 3) WASHER
SPEEDI
SLEEVE
BOLT
SHIM WASHER
LOCKNUT
COUPLING
BOLT
WASHER
COUPLING
SHIM
LOCKNUT (NOTE 1)
SPEEDI SHAFT
SLEEVE
SHIM
(NOTE 1)
NOTE 2
COUPLING
NOTES:
1. DO NOT EXCEED 0.100 IN. (2.54 MM) SHIM THICKNESS
IN EITHER OF THE TWO FLANGE LOCATIONS.
WASHER 2. 0.0100.020 IN. (0.2540.508 MM) GAP.
3. TORQUE 250 300 INCHPOUNDS (28.25 33.90 NM) PLUS
BOLT DRAG TORQUE OF 25 INCHPOUNDS (2.82 NM) MINIMUM,
200 INCHPOUNDS (22.60 NM) MAXIMUM.
G631012B
Figure 201. Fan Gearbox and InterConnecting Drive Shafts
Page 204
Revision 20 631530
MAINTENANCE MANUAL
5. Fan InterConnect Drive Shaft Do not exceed 0.100 inch (2.540

Replacement CAUTION mm) shim thickness in either of
the two flange locations. Shim thickness in
(Ref. Figure 201) both locations to be within 0.020 inch (0.508
mm) of each other.
A. Fan InterConnect Drive Shaft Removal
(4). Adjust the shim thickness between the
forward flange and the aft flange of the
(1). Remove fan inlet screen and fan interconnect drive shaft and the two
transmission cover (Ref. Sec. couplings.
533030).
(5). Install shims to obtain the specified
(2). Remove tailboom fairing and tailboom 0.0100.020 inch (0.2540.508 mm)
(Ref. Sec. 534030). gap. Install interconnect drive shaft
with eight mounting bolts and washers.
(3). Remove fan pitch control rod (Ref. Sec. Torque forward and aft mounting bolts
672030). 50 70 inchpounds (5.65 7.91 Nm)
plus drag torque.
To prevent damage to the shaft
CAUTION and couplings during and after
(6). Install fan pitch control; control rod
(Ref. Sec. 6720 30).
removal, provide level support for inter
connecting drive shaft. (7). Install tailboom and fairing (Ref. Sec.
534030).
(4). Remove four mounting bolts and
washers (2 places) and remove shims at (8). Check control rigging (Ref. Sec.
both ends of interconnect drive shaft, 672030).
remove interconnect drive shaft.
Retain shims for reinstallation. (9). Install access panels and covers (Ref.
Sec. 533030).
B. Fan InterConnect Drive Shaft
6. InterConnect Drive Shaft Inspection
Installation
Install interconnect drive shaft to obtain Consumable Materials

0.0100.020 inch (0.2540.508 mm) gap (Ref. Section 910000)
between the forward flange of the intercon- Item Nomenclature
nect drive shaft and the coupling aft flange as CM318 Primer
follows:
(1). Install interconnect drive shaft, install (1). Inspect drive shaft coupling for dents,
8 mounting bolts and washers except cracks, scratches, nicks, rust spots and
leave the 4 mounting bolts on the evidence of joint separation from shaft
forward flange of the interconnect or outside edges.
drive shaft backed off 0.0500.100 inch
(2). Inspect drive shaft tube between
(1.2702.540 mm) and torque the four
coupling for dents, scratches, cracks or
aft mounting bolts 50 70 inch
corrosion pits.
pounds (5.65 7.91 Nm).
(a). Measure depth and diameter of
(2). Pull and hold the coupling on the fan dents. Dents that blend smoothly into
gearbox Aft to remove end play. surrounding surface area with no
(3). With a feeler gage measure gap (aver- exceed 0.010 inch (0.254 mm) depth
age of 4 readings) between the flange of are acceptable. Dents not within
the interconnect drive shaft and the these limits require removal of shaft
coupling. from service.
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631530 Revision 20
MAINTENANCE MANUAL
(b). Measure depth of cracks, nicks, be more than 10 percent of original

corrosion pits or scratches; length material thickness.
and direction are not limited. Maxi-
mum depth allowed before rework is (a). Completely remove defect. Maintain
0.005 inch (0.127 mm). smooth transition into surrounding
surface.
(c). Check suspected cracks using dye (b). Use grade 400 wet or dry abrasive
penetrant. If crack indication ap- paper (CM801) for preliminary
pears, remove coating from area. finishing, and then polish with crocus
cloth (CM803).
(d). Reinspect suspected area using
magneticparticle or dyepenetrant (c). After rework, check shaft tube wall
methods. If crack does not reappear, thickness in repair area.
touch up cleaned area with primer
coating (CM318) and return part to (d). Apply primer coating (CM318) for
service. corrosion protection.
(3). Inspect all attaching hardware for 8. Transmission and Fan Coupling
serviceable condition. Discard and Inspection
replace defective hardware.
The following procedures is for inspection of
NOTE: Perform inspection steps (4). and (5). fan gearbox and fan input coupling. For
below only if shaft damage is suspected. information on Kamatics coupling inspection,
refer to Sec. 631000.
(4). Inspect shaft tube for outofround (1). Inspect coupling splined section and
condition, which shall not exceed 0.060 flange for cracks, scratch, nicks, dent
inch (1.524 mm). and corrosion pits. No cracks are
allowed. Maximum depth of other
(5). Inspect shaft for straightness. Shaft defects allowed before rework is 0.005
shall be straight within 0.030 inch inches.
(0.762 mm) at all locations relative to
centerlines of two flange mounting bolt (2). Inspect coupling speedisleeve for wear,
patterns. security of attachment to coupling.
7. InterConnect Drive Shaft Repair 9. Gearbox and Fan Coupling Repair

The following procedures is for repair of fan
Consumable Materials gearbox and fan input coupling. For informa-
(Ref. Section 910000) tion on Kamatic coupling repair, refer to Sec.
Item Nomenclature 631000.
CM318 Primer
CM801 Abrasive paper, silicon carbide Consumable Materials
CM803 Crocus cloth
Item Nomenclature
CM318 Primer
(1). Repair of drive shaft Kamatic flexible CM801 Abrasive paper, silicon carbide
type joint is limited. Repairs to spring CM803 Crocus cloth
area are not allowed. No cracks are
allowed.
(1). Repair damage to splines section and
(2). Repair drive shaft tube area damage flange of coupling that is no deeper
that is no deeper than 0.005 inch (0.127 than 0.005 inch (0.127 mm). Use
mm). Maximum depth after repair is abrasive paper (CM801) grade 400
0.010 inch (0.254 mm). The maximum 600 and crocus cloth (CM803) to
thickness of material removed shall not completely remove and polish out
Page 206
Revision 20 631530
MAINTENANCE MANUAL
defect. Maximum depth after rework is

0.010 inch (0.254 mm). Apply primer Special Tools
(CM318) to repaired area. (Ref. Section 910000)
Item Nomenclature
(2). After rework, check coupling wall ST604 Coupling socket
thickness in repair area. The maximum
thickness of material removed shall not
be more than 10 percent of original A. Transmission Coupling / Fan Coupling
material thickness. Removal
(1). Remove nut from shaft using coupling
10. Transmission Coupling / Fan Coupling socket (ST604) and coupling holding
Replacement fixture tool; remove coupling.
B. Transmission Coupling / Fan Coupling
(Ref. Figure 202) Installation
(1). Slide coupling onto support shaft.
(Ref. Section 910000) (2). Install nut using antiseize compound
Item Nomenclature (CM113) as required. Torque nut to 800
1000 inchpounds (90.39 112.98
CM113 Antiseize compound low temperature Nm) plus drag torque using coupling
socket (ST604) and holding fixture.
G631023A
Figure 202. Fan Interconnect Drive Shaft Coupling Installation
Page 207
631530 Revision 20
MAINTENANCE MANUAL
Page 208
Revision 43 631530
MAINTENANCE MANUAL
Section
632000
369D25100 Main
Transmission
(369D/E/FF 500N)
MAINTENANCE MANUAL
P/N 369D25100
369D25100 MAIN TRANSMISSION
1. Main Transmission (7). Drain oil from transmission.
The main transmission is secured to the (8). Disconnect tail rotor output shaft seal
underside of the main rotor mast support drain line, input shaft seal drain line
structure pan by four structure bolts, washers, and two hoses that attach to lubrication
and nuts. The transmission is a twostage pump.
speed reduction unit. The first reduction stage
is for the tail rotor drive system and accessory
(9). With assistance, support transmission;
drive trains. The second stage is for further
then remove four nuts and washers
reducing rpm for the main rotor. The transmis-
from mast support structure studs.
sion housing is magnesium alloy. The accesso-
ry gear train drives a rotor tachometer
generator and the transmission oil pump that Lower transmission with ex-
CAUTION treme care to prevent contact
are mounted on drive pads at the aft end of the
transmission. The transmission is cooled by air between tail rotor drive coupling and sur-
drawn through a cooling blower and routed rounding structure. Any dents, nicks or
through the transmission oil cooler. Access to scratches on coupling diaphragm requires
the main transmission is attained by entrance that coupling be scrapped. Use care to pro-
into the passenger compartment. tect oil pressure sender and chip detector
terminal studs from damage during handl-
2. Main Transmission Buildup and ing or when placing transmission on any
Replacement surface.
A. Main Transmission Removal (10). With assistance, carefully lower

transmission from mounting studs.
(Ref. (Ref. Figure 201)
NOTE: Cover top opening of transmission to
(1). Remove sound insulation and transmis- prevent entry of foreign material. Residual
sion access covers (Ref. Sec. 524000). operating lubricant is an approved preser-
vative for transmission shipment or storage.
(2). Remove main transmission drive shaft
(Ref. Sec. 631000).
(11). Perform the following steps as applica-
(3). Remove cooling blower (Ref. Sec. ble to strip main transmission.
632100).
(a). Remove tachometer generator.
(4). Remove antitorque drive shaft (Ref.
Sec. 6315). (b). Remove coupling bolt, coupling and
shim from tail rotor output shaft.
NOTE: Removal of main rotor drive shaft (step
e. below) is optional. If help is not available (12). Remove coupling bolt, coupling, shim,
to rotate rotor hub for spline alignment, drive pulley and pulley guard from
shaft removal simplifies reinstallation of main transmission input shaft.
transmission.
(5). Remove main rotor drive shaft (Ref. (a). Remove input shaft seal drain
Sec. 631000). connector (Ref. Figure 202).
(6). Disconnect wires from tachometer (b). Install suitable covers and plugs to
generator, two chip detectors and oil protect all openings, including
pressure sender. threaded holes.
Page 201
632000 Revision 20
MAINTENANCE MANUAL
P/N 369D25100
COUPLING BOLT
COUPLING (KAMATIC)
MAIN ROTOR
DRIVE SHAFT
MAST BASE TAIL ROTOR

DRIVE SHAFT
FAILSAFE SOCKET
(NOTE 2)
COUPLING
(BENDIX)
DEBRIS
FAILSAFE COUPLING
OUTPUT SHAFT COVER
BOLT
LAMINATED SHIM
OUTPUT SHAFT
COOLING BLOWER
FILLER
PLUG
PULLEY GUARD COUPLING

ORING INPUT SHAFT
(NOTE 1)
PULLEY
SEAL INTERNAL
SEAL WRENCHING
(NOTE 3) (NOTE 3) LAMINATED SHIM BOLT

SAFETY WIRE

SEALANT
(NOTE 4)
NOTES:
1. ORING MUST BE CEMENTED IN PLACE BEFORE INSTALLING TRANSMISSION.
2. NOT USED WITH KAMATIC COUPLING.
3. SEAL MUST BE CEMENTED IN PLACE BEFORE INSTALLING TRANSMISSION.
FILLER SEAL INSTALLATION 4. FILL CUT IN SEAL WITH SEALANT (CM430).
G632004B
Figure 201. 369D25100 Main Transmission Installation
Page 202
Revision 20 632000
MAINTENANCE MANUAL
P/N 369D25100
B. Main Transmission Installation especially area contacted by Oring on
top of transmission.
(Ref. Figure 201)
Damage to main rotor drive
CAUTION shaft or main transmission
Consumable Materials splines can occur during installation. Care
(Ref. Section 910000) should be taken while meshing drive shaft
Item Nomenclature splines into transmission output splines to
CM111 Grease, aircraft prevent damage.
(3). With assistance, slowly and evenly lift
CM121 Preservation oil and position transmission in place on
CM125 Oil mounting studs.
CM126 Oil, turbine
(4). Install four washers and nuts; torque to
CM234 Solvent, drycleaning 60 80 inchpounds (6.78 9.04
CM417 Cement Nm).
(5). If transmission is new, drain any
CM430 Sealant, solvent resistant residual preservative oil. Service
transmission with lubricating oil
(1). Perform the following steps as applica- (CM125 or CM126) (Ref. Sec.
ble to build up main transmission prior 120000).
to installation. (6). Connect wiring to tachometer genera-
(a). Install one preliminary 0.010 inch tor, two chip detectors and oil pressure
(0.250 mm) shim on tail rotor output switch.
shaft to prevent coupling bolt from (7). Install antitorque drive shaft (Ref.
bottoming in shaft. Sec. 631510/30).
(b). Coat coupling splines with grease When reinstalling main rotor
(CM111) and coat bolt threads with CAUTION drive shaft, check that there is
antiseize compound (CM112) before no gap between shaft mounting flange and
assembly. Install shaft coupling and rotor hub before tightening installation
temporarily tighten coupling bolt to bolts. Gap indicates that shaft splines are
approximately 250 inchpounds not correctly meshed in transmission.
(28.25 Nm).
(8). If main rotor drive shaft has been
(c). Install tachometer generator. With removed, apply coating of lubricating
rotor brake installed, ensure electri- oil (CM121) on shaft before reinstalla-
cal receptacle is at 11 oclock position. tion and install drive shaft (Ref. Sec.
631000).
(d). Install input shaft seal drain connec-
tor, bonding it in place with sealing (9). Connect tail rotor output shaft seal
compound (CM425). drain line and input shaft seal drain
line and two hoses that attach to
(e). Bond main rotor output shaft Oring lubrication pump.
in place with cement (CM417).
(10). Install cooling blower (Ref. Sec.
(f). Bond filler seal to transmission with 632100).
cement (CM417). (11). Coat input drive coupling splines with
(g). If filler is safetied to case bolt, cut a grease (CM111) and coat bolt threads
small section from seal and bond in with antiseize compound (CM112)
place. After bonding, fill gap in seal before assembly. Install pulley guard,
with sealant (CM430). drive pulley, shim, coupling and
coupling bolt and temporarily tighten
(2). Use clean, absorbent cloth to clean pan coupling bolt to approximately 250
beneath main rotor mast support, inchpounds (28.25 Nm).
Page 203
632000 Revision 20
MAINTENANCE MANUAL
P/N 369D25100
NOTE: Refer to Sec. 631000, Main Transmis- 4. Main Transmission Repair Procedure
sion Drive Shaft Installation for coupling
shimming, coupling torque and drive shaft (Ref. Figure 201) Replace electrical compo-
installation. nents, breatherfiller, filler screen, externally
accessible Orings, lubrication pump, filter,
input shaft oil seal and tail rotor output shaft
(12). Install main transmission drive shaft oil seal if defective. Dents in outer surface of
(Ref. Sec. 631000). transmission housing deeper than 0.10 inch or
covering more than 0.60 square inch (3.87 cm2)
area require replacement of transmission (for
(13). Ground run helicopter (refer to appro- repairs not covered in this section, Ref. COM).
priate PFM) and check drive system for This procedure is applicable to dents not
excessive vibration and unusual noise. exceeding specified limits.
Verify absence of oil overtemperature
and low pressure indications. Inspect Consumable Materials
for oil leakage. (Ref. Section 910000)
Item Nomenclature
(14). Install access covers and sound insula-
CM318 Primer
tion (Ref. Sec. 524000).
3. Main Transmission Inspection Procedure
NOTE: Any evidence of lubricating oil leakage
(Ref. Figure 201) The following procedures provide in a repair area requires replacement of
information for checking the main transmission transmission.
for oil leakage and mechanical defect.
(1). Clean area with solvent (CM234) and
(1). Remove sound insulation and transmis- remove sharp edges with grade 320
sion access covers (Ref. Sec. 524000). abrasive paper (CM801).
(2). Apply coat of primer (CM318) on
repaired surface.
(2). Inspect transmission for oil leaks,
cracks, corrosion, secure electrical (3). If dent is deeper than 0.030 inch (0.76
connections and correct oil level. mm), fill depression with epoxy adhe-
Evaluate oil leakage according to Fluid sive (CM411) and blend to surrounding
Leak Analysis. surfaces.
(4). Touch up reworked area with paint
Inspect all fluid lines for ade- (Ref. Sec. 2030).
CAUTION quate clearance between struc-
ture and components. Vibration may cause 5. Input Drive Assembly Oil Leakage
chafing of lines and subsequent leaking. Repair Procedure
(Ref. Figure 202) Use the following repair
procedure when oil leakage occurs between the
(3). Inspect four mounting flanges on main main transmission housing and the pinion
transmission housing for corrosion and bearing sleeve flange. Replace the
cracks. Check that transmission 369D251843 Oring as follows.
mounting studs and nuts are secure.
This should be accomplished from
fuselage interior as well as exterior at Consumable Materials
main rotor mast base. (Ref. Section 910000)
Item Nomenclature
CM218 Alcohol, denatured
(4). Check that all safety wiring is intact.
Page 204
Revision 36 632000
MAINTENANCE MANUAL
P/N 369D25100
(1). Remove the shaft interconnect, trans- (12). Remove alignment bolts and install
mission input coupling, drive pulley assembly aid tool halves between
and guard, and cooling blower assembly Oring and input bearing sleeve flange.
(Ref. Sec. 632100). (Refer to Figure 203 for locally fabri-
cated assembly aid tool.)
(2). Drain oil from input drive assembly
through the lower chip detector plug (13). Install attaching hardware in blower
(Ref. Sec. 120000). mount, input pinion bearing sleeve, and
assembly aid tool.
(3). Remove attaching hardware securing
blower mount assembly (Ref. Sec. (14). Tighten attaching hardware as follows:
632100).
(a). Maintain an inward preload of the
(4). Install four alignment bolts in place of assembly aid tool halves against the
attaching hardware for blower mount input pinion bearing sleeve while
assembly. (Use any type of 2.00 inch tightening the four attaching bolts
(5.08 cm) length x 1/428 diameter equally.
bolt.)
(b). Tighten hardware until attaining a
(5). Install slide hammer tool on input drive positive clampup between the main
assembly pinion. housing, assembly aid tool halves,
and input pinion bearing sleeve
NOTE: flange.
D It may be necessary to heat main housing
to move input drive assembly. (15). Remove attaching hardware and slide
out the assembly aid tool halves.
D Any movement of more than 0.150 inch
(3.81 mm) may cause disengagement of
(16). Ensure the Oring is seated in main
scavenge pump drive.
housing groove.
(6). Gently tap input drive assembly away
from main housing no more than 0.150 (17). When Oring is seated correctly,
inch (3.81 mm) to gain access to Oring reinstall input pattern shim between
between main housing and input main housing and input pinion bearing
pattern shim. sleeve flange and reinstall hardware.
(7). Remove slide hammer tool from input (18). Tighten attaching hardware as follows:
drive assembly pinion.
(a). Maintain an inward preload on input
(8). If required, cut defective Oring for pattern shim during the tightening
removal. sequence.
(9). Clean and inspect pattern shim for (b). Torque attaching hardware 65 75
distortion and ensure no overlap inchpounds (7.34 8.47 Nm).
condition exists at butt/split line of
shim. (19). Inspect pattern shim to ensure no
overlap condition exists at butt/split
(10). Clean area between main housing and line.
input drive sleeve with alcohol (CM218)
to remove paint chips or other foreign (20). Reinstall the shaft interconnect,
matter. transmission input coupling, drive
pulley and guard, and cooling blower
(11). Install new 369D251843 Oring by assembly (Ref. Sec. 632100).
slipping over blower mount. Seat
Oring in contact with the main (21). Add oil to input drive assembly (Ref.
housing. Sec. 120000).
Page 205
632000 Revision 36
MAINTENANCE MANUAL
P/N 369D25100
ASSEMBLY AID TOOL

COOLING BLOWER
MOUNTING BRACKET
SCAVENGE
PUMP DRIVE
(NOTE 1)
COOLING BLOWER
INPUT DRIVE PULLEY SPACER
PINION CHIP DETECTOR
INPUT SHAFT
SELFCLOSING
DRAIN VALVE
INPUT SHAFT
SEAL DRAIN NOTE 2
CONNECTOR
INPUT PATTERN
SHIM HALVES
NOTE 5
ORINGS
CHANGE THIS
ORING ONLY
NOTES:
1. MOVEMENT IN EXCESS OF
0.15 IN. (3.81 MM) MAY CAUSE
DISENGAGEMENT OF SCAVENGE
CLAMPUP PUMP DRIVE.
SHIM 2. INSTALL SLIDE HAMMER ON
INPUT DRIVE ASSEMBLY PINION.
3. INSTALL BETWEEN ORING AND
FLANGE ON INPUT PINION
BEARING SLEEVE.
ASSEMBLY AID 4. USE SAME MOUNTING HOLES
TOOL HALVES FOR ALIGNMENT BOLTS.
(NOTE 3) 5. MOUNT SHIM WITH SPLIT AT
3 AND 9 OCLOCK POSITION.
INPUT PINION 0.0000.030 IN. (0.0000.762 MM)
BEARING SLEEVE MAXIMUM GAP ALLOWED.
MOUNTING
ORINGS HARDWARE
(NOTE 4)
BLOWER MOUNT
ASSEMBLY
G632027A
Figure 202. Input Drive Assembly ORing Replacement
Page 206
Revision 20 632000
MAINTENANCE MANUAL
P/N 369D25100
1.50 (3.81 CM) 1.50 (3.81 CM) 0.257 (0.653 CM) DIA
(TYP) (TYP) (4 PLS)
0.375 (9.53 MM)

(REF)
1.50 (3.81 CM)

(TYP)
3.750 (9.53 CM)
3.350 (8.51 CM) DIA

1.50 (3.81 CM)
(TYP)
1.250 (3.05 CM)

(4 PLS)
0.375 (9.53 MM)
(REF)
1.150 1.850
(2.92 CM) 4.70 CM) SHIM SPLIT
(4 PLS) (4 PLS) (2 PLS)
6.00
(15.24 CM)
NOTES:
1. MATERIAL 0.070 INCH ( 1.78 MM) CRES STEEL.
2. ALL DIMENSIONS ARE IN INCHES (CM).
G632028A
Figure 203. Assembly Aid Tool for Input Drive

632000 Revision 20
MAINTENANCE MANUAL
Section
632025
369F5100 Main
Transmission
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
P/N 369F5100
369F5100 MAIN TRANSMISSION
1. Main Transmission (8). Disconnect antitorque output shaft
seal drain line, input shaft seal drain
The main transmission is secured to the line and two hoses that attach to
underside of the main rotor mast support lubrication pump.
structure pan by four structure bolts, washers,
and nuts. The transmission is a twostage NOTE: The following step will require an assis-
speed reduction unit. The first reduction stage tant to hold the transmission mount bolts
is for the tail rotor drive system and accessory from the top of the helicopter and an assis-
drive trains. The second stage is for further tant to remove the nuts and washers.
reducing rpm for the main rotor. The transmis-
sion housing is magnesium alloy. The accesso- (9). With assistance, support transmission;
ry gear train drives a rotor tachometer then remove hardware securing
generator and the transmission oil pump that transmission to mast support structure.
are mounted on drive pads at the aft end of the
transmission. The transmission is cooled by air Lower transmission with ex-
drawn through a cooling blower and routed CAUTION treme care to prevent contact
through the transmission oil cooler. Access to between antitorque drive coupling and sur-
the main transmission is attained by entrance rounding structure. Any dents, nicks or
into the passenger compartment. scratches on coupling requires that coupling
be scrapped. Use care to protect oil pressure
2. Main Transmission Replacement sender and chip detector terminal studs
from damage during handling or when plac-
A. Main Transmission Removal ing transmission on any surface.
(Ref. Figure 201) (10). With assistance, carefully lower

transmission.
(1). Remove sound insulation and transmis-
sion access covers. NOTE: Cover top opening of transmission to
prevent entry of foreign material. Residual
(2). Remove main transmission drive shaft operating lubricant is an approved preser-
(Ref. Sec. 631000). vative for transmission shipment or storage.
(3). Remove cooling blower (Ref. Sec. B. Main Transmission Installation

632100).
(Ref. Figure 201)
(4). Remove antitorque drive shaft (Ref.
Sec. 631510/30).
NOTE: Removal of main rotor drive shaft is op- (Ref. Section 910000)
tional. If help is not available to rotate rotor Item Nomenclature
hub for spline alignment, shaft removal sim- CM111 Grease, aircraft
plifies reinstallation of transmission. CM112 Antiseize compound high temperature
(5). Remove main rotor drive shaft (Ref. CM121 Preservation oil
Sec. 631000). CM125 Oil
(6). Disconnect wires from tachometer

generator, two chip detectors and oil (1). Use clean, absorbent cloth to clean pan
pressure sender. beneath main rotor mast support,
especially area contacted by Oring on
(7). Drain oil from transmission. top of transmission.
Page 201
632025 Revision 20
MAINTENANCE MANUAL
P/N 369F5100
MAIN ROTOR DRIVE SHAFT
MAST BASE
COUPLING COUPLING
(KAMATIC) BOLT
LAMINATED
SHIM
TAIL ROTOR
OUTPUT DRIVESHAFT
SHAFT
OUTPUT SHAFT
DEBRIS
COVER
COOLING BLOWER
FILLER
INPUT
SHAFT
COUPLING
ORING
(NOTE) PULLEY
GUARD
PULLEY
INTERNAL
WRENCHING BOLT
NOTE:
ORING MUST BE CEMENTED IN PLACE
BEFORE INSTALLING TRANSMISSION.
G632032A
Figure 201. 369F5100 Main Transmission Installation
Page 202
Revision 20 632025
MAINTENANCE MANUAL
P/N 369F5100
Damage to main rotor drive with antiseize compound (CM112)
CAUTION shaft or main transmission before assembly.
splines can occur during installation. Care
should be taken while meshing drive shaft When installing pulley and
CAUTION guard, make sure the spring pin
splines into transmission output splines to
prevent damage. in pulley is fully engaged inside hole in
pulley guard. If the spring pin does not align
NOTE: The following procedure will require correctly with hole in pully guard, the
the assistance of another person. torque will be incorrect.
(2). With assistance, slowly and evenly lift (11). Install pulley guard, drive pulley, shim,
and position transmission in place. coupling and coupling bolt and tempo-
rarily tighten coupling bolt to approxi-
(3). Install four washers and nuts; torque to mately 250 inchpounds (28.25 Nm).
900 1100 inchpounds (101.69
124.28 Nm) plus drag torque. NOTE: Refer to Sec. 631000, Main Transmis-
sion Drive Shaft Installation and for cou-
(4). If transmission is new, drain any pling shimming, coupling torque and drive
residual preservative oil. Service shaft installation.
transmission with lubricating oil
(CM125) (Ref. Sec. 120000). (12). Install main transmission drive shaft
(Ref. Sec. 631000).
(5). Connect wiring to tachometer genera-
tor, two chip detectors and oil pressure (13). Ground run helicopter (refer to appro-
switch. priate PFM) and check drive system for
excessive vibration and unusual noise.
(6). Install antitorque drive shaft (Ref.
Verify absence of oil overtemperature
Sec. 631510/30).
and low pressure indications. Inspect
When reinstalling main rotor for oil leakage.
CAUTION drive shaft, check that there is
no gap between shaft mounting flange and (14). Install access covers and sound insula-
rotor hub before tightening installation tion.
bolts. Gap indicates that shaft splines are 3. Main Transmission Stripping
not correctly meshed in transmission.
(Ref. Figure 202)
(7). If main rotor drive shaft has been
removed, apply coating of preservative (1). Remove tachometer generator.
oil (CM121) on shaft before reinstalla-
tion and install drive shaft (Ref. Sec. (2). Remove coupling bolt, coupling and
631000). shim from antitorque output shaft.
(8). Connect antitorque output shaft seal (3). Remove coupling bolt, coupling, shim,
drain line and input shaft seal drain drive pulley and pulley guard from
line and two hoses that attach to main transmission input shaft.
lubrication pump.
(4). Remove input shaft seal drain connec-
(9). Install cooling blower (Ref. Sec. tor (Ref. Sec. 120000).
632100).
(5). Install suitable covers and plugs to
(10). Coat input drive coupling splines with protect all openings, including threaded
grease (CM111) and coat bolt threads holes.
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632025 Revision 41
MAINTENANCE MANUAL
P/N 369F5100
OUTPUT OUTPUT
PINION COUPLING
ROTOR
BRAKE ANTITORQUE
OIL FILLER DRIVE SHAFT
OIL COOLER
BLOWER
COUPLING BOLT
CHIP DETEC-
TORS
DRIVE PULLEY
B B
INPUT
COUPLING ENGINETOTRANSMISSION
DRIVE SHAFT
SNUBBER (600N
ADAPTER (369D/E/FF 500N TACH GENERATOR
PACKING
PRESSURE SWITCH LOCK WIRE
TRANSMISSION
OIL FILTER
JUMPER ASSEMBLY
DIFFERENTIAL PRESSURE INDICATOR (IM-

PENDING BYPASS INDICATOR)
VIEW AA
LOOKING FORWARD
VIEW BB
LOOKING UP
CSP102009C
Figure 202. 369F5100 Main Transmission BuildUp
Page 204
Revision 28 632025
MAINTENANCE MANUAL
P/N 369F5100
4. Main Transmission BuildUp (6). Using a new Oring, install oil pressure
switch and safety with lockwire
(Ref. Figure 202) (CM702).
(7). Bond main rotor output shaft Oring in

Consumable Materials place with cement (CM417).
Item Nomenclature (8). Using two new Orings, install exten-
sion, screen and filler on transmission.
CM111 Grease, aircraft Use 369A5169 shims to ensure filler is
CM112 Antiseize compound high temperature angled no more than 30 from center
facing forward.
CM417 Cement
CM425 Sealing compound 5. Main Transmission Inspection Procedure
CM702 Lockwire CRES
(Ref. Figure 201) The following procedures
provide information for checking the main
(1). Install one preliminary 0.010 inch transmission for oil leakage and mechanical
(0.254 mm) shim on antitorque output defect.
shaft to prevent coupling bolt from
bottoming in shaft. (1). Remove sound insulation and transmis-
sion access covers.
(2). Coat coupling splines with grease (2). Inspect transmission for oil leaks,
(CM111) and coat bolt threads with cracks, corrosion, secure electrical
antiseize compound (CM112) before connections and correct oil level.
assembly. Install shaft coupling and Evaluate oil leakage according to Fluid
temporarily tighten coupling bolt to Leak Analysis.
approximately 250 inchpounds
(28.25 Nm). Inspect all fluid lines for ade-
CAUTION quate clearance between struc-
(3). Install tachometer generator. With ture and components. Vibration may cause
rotor brake installed, ensure electrical chafing of lines and subsequent leaking.
receptacle is at 11 oclock position.
Torque nuts to 30 40 inchpounds (3). Inspect four mounting flanges on main
(3.39 4.52 Nm) plus drag torque. transmission housing for corrosion and
cracks. Check that transmission
mounting nuts are secure.
(4). Install input shaft seal drain connector,
bonding it in place with sealing com-
(4). Check that all safety wiring is intact.
pound (CM425).
6. Main Transmission Repair Procedure
NOTE: On the 369F5100 transmission, the oil
pressure switch is mounted on the bottom, (Ref. Figure 201) Replace electrical compo-
right side, facing down. nents, breatherfiller, filler extension, filler
screen, externally accessible Orings, scavenge
(5). 600N: Using a new Oring, install pump, lubrication pump, filter, input shaft oil
147D2 snubber and torque to 155 seal and antitorque output shaft oil seal if
165 inchpounds (17.51 18.64 Nm). defective. Dents in outer surface of transmis-
369D/E/FF 500N: Using a new sion housing deeper than 0.10 inch (2.54 mm)
Oring, install 369F51951 adapter or covering more than 0.60 square inch (3.87
with teflon tape wrapped around cm2) area require replacement of transmission
threads as required and torque to 155 (for repairs not covered in this section, Ref.
165 inchpounds (17.51 18.64 Nm). CSPCOM5).
Page 205
632025 Revision 24
MAINTENANCE MANUAL
P/N 369F5100
This procedure is applicable to dents not (3). Remove attaching hardware securing
exceeding specified limits. blower mount assembly.
(4). Using NAS60364 jack screws at two
Consumable Materials corners of the input quill, begin pulling
(Ref. Section 910000) the input quill from the transmission
Item Nomenclature housing. As required, operators may
CM234 Solvent, drycleaning use 0.51.0 inch (12.7025.40 mm) bar
CM318 Primer stock or equivalent as spacers to put
under the jack screws to assist
removing the input quill.
NOTE: It may be necessary to heat main hous-
ing to move input drive assembly.
NOTE: Any evidence of lubricating oil leakage
in a repair area requires replacement of (5). Gently screw input drive assembly
transmission. away from main housing no more than
0.150 inch (3.81 mm) to gain access to
(1). Clean area with solvent (CM234) and Oring between main housing and
remove sharp edges with grade 320 input pattern shim.
abrasive paper (CM801).
(6). Remove jack screws from input drive
(2). Apply coat of primer (CM318) on assembly pinion.
repaired surface.
(7). If required, cut defective Oring for
(3). If dent is deeper than 0.030 inch (0.762 removal.
mm), fill depression with epoxy adhe-
sive (CM411) and blend to surrounding (8). Clean and inspect pattern shim for
surfaces. distortion and ensure no overlap
condition exists at butt/split line of
(4). Touch up reworked area with paint shim.
(Ref. Sec. 203000).
(9). Clean area between main housing and
7. Input Drive Assembly Oil Leakage input drive sleeve with alcohol (CM218)
Repair Procedure to remove paint chips or other foreign
matter.
A. Input Pinion ORing Replacement
(10). Install new Oring by slipping over
(Ref. Figure 203) Use the following repair blower mount. Seat Oring in contact
procedure when oil leakage occurs between the with the main housing.
main transmission housing and the pinion
bearing sleeve flange. (11). Remove alignment bolts and install
attaching hardware in blower mount
and input pinion bearing sleeve.
(Ref. Section 910000) (12). Tighten attaching hardware as follows:
Item Nomenclature
(a). Tightening the four attaching bolts
CM218 Alcohol, denatured equally.
(b). Tighten hardware until attaining a
(1). Remove the shaft interconnect, trans- positive clampup between the main
mission input coupling, drive pulley housing and input pinion bearing
and guard, and cooling blower assembly sleeve flange.
(Ref. Sec. 632100).
(13). Remove attaching hardware.
(2). Drain oil from input drive assembly
through the lower chip detector plug (14). Ensure the Oring is seated in main
(Ref. Sec. 120000). housing groove.
Page 206
Revision 29 632025
MAINTENANCE MANUAL
P/N 369F5100
ORING
SLEEVE
CRUSH SEAL
INPUT SEAL
ORING FAN MOUNT
BEARING RETAINER
BOLT WASHER
BOLT
INPUT LABYRINTH SEAL

WASHER
INPUT PINION
LOCKNUT
INPUT LOCKWASHER
NOSE BEARING
INPUT
BEARING PULLEY SHIM
SHIM
SPACER
INPUT BEARING SHIM
ORINGS ORING
INPUT SHAFT OUTER SLEEVE
INPUT BEARING
INPUT THRUST BEARING
ORING G632033B
Figure 203. Drive Assembly ORing Replacement

(15). When Oring is seated correctly, (17). Inspect pattern shim to ensure no
reinstall input pattern shim between overlap condition exists at butt/split
main housing and input pinion bearing line.
sleeve flange and reinstall hardware.
(16). Tighten attaching hardware as follows: (18). Reinstall the shaft interconnect,
(a). Maintain an inward preload on input transmission input coupling, drive
pattern shim during the tightening pulley and guard, and cooling blower
sequence. assembly.
(b). Torque attaching hardware 50 70

inchpounds (5.65 7.91 Nm) plus (19). Service the transmission (Ref. Sec.
drag torque. 120000).
Page 207
632025 Revision 29
MAINTENANCE MANUAL
P/N 369F5100
B. Input Pinion Seal Replacement (c). Insert adapter and breaker bar into
socket.
(Ref. Figure 203) Use the following repair
procedure when oil leakage occurs at the input (d). Turn locknut removal tee counter
pinion seal. clockwise, while holding spline socket
stationary, to remove nut.
NOTE:
(6). Using seal removal tool, remove seal
D If replacing a magnetic seal with a la- from input quill.
brynth seal, a speedisleeve must be
installed (Ref. COM, Sec. 632025). (7). Clean sealant from seal seating surface
D If installing a 369F51651 labrynth seal, in blower mount with denatured alcohol
seal must be modified (Ref. COM, Sec. (CM218).
632025). (8). Allow to air dry.
(9). Apply sealing compound (CM425) to
seal edge and mating surface in blower
mount.
Item Nomenclature
CM112 Antiseize compound high temperature (10). Insert seal into blower mount.
CM218 Alcohol, denatured (11). Clean any excess sealant and allow
CM425 Sealing compound sealant to cure per manufacturers
instructions.
Special Tools
(12). Apply antiseize compound (CM112) to
nonserrated threads on pinion and
Item Nomenclature
install locknut.
N/A 369F5100ATP1 Locknut removal tool
NOTE: The following procedure requires two
people to accomplish.
(1). Remove the main transmission drive
shaft (Ref. Sec. 631000, Main (a). Insert tee over locknut and put
Transmission Drive Shaft Replace- cheater bar over one ear of tee.
ment). (b). Insert socket through center of tee to
(2). Remove nut from transmission input engage splines on input shaft.
coupling, drive pulley and guard (Ref. (c). Insert adapter and breaker bar into
Sec. 631000, Main Transmission socket.
Drive Shaft Replacement), keep all
shims with coupling. (d). Turn input shaft counterclockwise,
while holding locknut stationary, to
(3). Drain oil from input drive assembly install nut.
through the lower chip detector plug
(Ref. Sec. 120000). (e). Torque nut to 250 footpounds (339
Nm). Loosen locknut and retorque
(4). Remove lockwasher. to 183 225 footpounds (248
305 Nm).
(5). Using locknut removal tool, remove
locknut. (13). Install lockwasher.
NOTE: The following procedure requires two (14). Reinstall input coupling with shims
people to accomplish. previously removed (Ref. Sec.
631000, Main Transmission Drive
(a). Insert tee over locknut and put Shaft Replacement).
cheater bar over one ear of tee.
(15). Reinstall main transmission drive shaft
(b). Insert socket through center of tee to (Ref. Sec. 631000, Main Transmission
engage splines on input shaft. Drive Shaft Replacement).
Page 208
Revision 29 632025
MAINTENANCE MANUAL
P/N 369F5100
(16). Service transmission (Ref. Sec. 9. Main Transmission RunIn Procedure
120000).
New (from the factory) transmissions must
8. Main Transmission Filter Replacement have a runin period to remove the corrosion
preventive coating from the coastside of the
(Ref. Figure 202) drive gears. If not done at installation, the
coating will come off, over time, and cause the
(1). Remove interior trim and blower access impending bypass button to pop.
door.
(1). Fly aircraft normally, monitoring the
(2). Position container or cloth to catch transmission chip detectors for metal
residual oil. Loosen and remove filter particles, for the first 10 hours.
housing by turning counterclockwise.
NOTE: Ignore the impending bypass indicator
(3). Remove filter element. in the first 10 hours of flight.
(4). Inspect filter element for metal par- (2). During the first 10 hours of flight time,
ticles. If metal particles are present, perform at least three partial autorota-
remove main transmission chip detec- tions (Ref. Pilots Flight Manual) to load
tors and inspect for other evidence of the transmission on the coast side of
internal failure in gearbox. the gears.
(5). If filter is excessively clogged, flush NOTE: Each autorotation should be at least 30
system and check filter bypass valve for seconds in duration.
operation (Ref. COM).
(3). After 10 hours flight time has elapsed,
(6). Install new filter element and new replace filter element (Ref. Main
Orings. Transmission Filter Replacement).
(7). Install housing and torque to 90 100 NOTE:
inchpounds (10.17 11.30 Nm). D Coating particles are black in color. Some
silver nonmagnetic metallic particles
(8). If necessary, replenish transmission oil
could be in the filter bowl, which are mag-
supply.
nesium machining debris from manufac-
(9). Perform ground runup of helicopter and turing.
check for oil leakage. D Flushing transmission oil is preferred but
not necessary.
(10). Reinstall, in order, blower access door
and interior trim. (4). Reset the impending bypass indicator.

632025 Revision 29
MAINTENANCE MANUAL
Section
632100
Main Transmission
Lubrication and
Cooling System
(369D/E/FF
500/600N)
MAINTENANCE MANUAL

MAINTENANCE MANUAL
MAIN TRANSMISSION LUBRICATION

AND COOLING SYSTEM
1. Main Transmission Lubrication System (4). Ground run helicopter (Ref. PFM) and
check pump interface for leaks per
The main transmission lubrication system Fluid Leak Analysis (Ref. Sec. 6320).
consists of a lubrication pump driven by the Verify that pressure warning light is
transmission, an oil filter, oil cooler, oil cooler not on at 55% N2.
bypass valve, oil temperature sender, oil
pressure sender, liquid level plug, two chip (5). Reinstall access covers and sound
detectors, a drain line from the tail rotor insulation.
output shaft seal and a drain line from the
input shaft seal.
3. Main Transmission Lubrication Pump
2. Main Transmission Lubrication Pump Replacement (369F5100 Transmission)
Replacement (369D25100 Transmission)
(Ref. Figure 402)
(Ref. Figure 401)
A. Main Transmission Lubrication Pump
A. Main Transmission Lubrication Pump Removal (369F5100 Transmission)
Removal (369D25100 Transmission)
(1). Remove sound insulation and transmis-
(1). Remove sound insulation and transmission access covers (Ref. Sec. 5240).
sion access covers.
(2). Remove hardware that secure pump
(2). Remove hardware that secure pump
housing to mounting pad.
housing to mounting pad.
(3). Remove pump and discard three (3). Remove pump and discard Orings.
Orings.
B. Main Transmission Lubrication Pump
B. Main Transmission Lubrication Pump Installation (369F5100 Transmission)
Installation (369D25100 Transmission)
Item Nomenclature
CM114 Petrolatum
CM114 Petrolatum
(1). Install new Orings in ports and in

(1). Install new Orings in ports and in
groove of pump sleeve. Apply light
groove of pump sleeve. Apply light
coating of petrolatum (CM114) to both
coating of petrolatum (CM114) to both
Orings and mating bores in transmis-
sion to prevent damage to Orings.
sion to prevent damage to Orings.
(2). Align square drive of pump with drive (2). Align square drive of pump with drive
shaft in transmission and carefully shaft in transmission and carefully
press pump into place. press pump into place.
(3). Install attaching hardware; torque to (3). Install attaching hardware; torque to
50 70 inchpounds (5.65 7.91 40 50 inchpounds (4.52 5.65 Nm)
Nm). plus drag torque.
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632100 Revision 20
MAINTENANCE MANUAL
MAIN TRANSMISSION
LUBRICATION PUMP
ORINGS
ROTATED
632008
Figure 401. Main Transmission Lubrication Pump (369D25100 Transmission)
Page 402
Revision 20 632100
MAINTENANCE MANUAL
SCAVENGE
OIL PUMP
LUBRICATION
PUMP
LOOKING FORWARD
LUBRICATION
PUMP
0RINGS
MAIN
TRANSMISSION
DIFFERENTIAL PRESSURE INDICATOR

(IMPENDING BYPASS INDICATOR)
SCAVENGE OIL PUMP
0RINGS
6G63002A
Figure 402. Main Transmission Lubrication Pump (369F5100 Transmission)
Page 403
632100 Revision 28
MAINTENANCE MANUAL
(4). Ground run helicopter (Ref. PFM) and tors and inspect for other evidence of
check pump interface for leaks per internal failure in gearbox.
Fluid Leak Analysis (Ref. Sec. 6320).
Verify that pressure warning light is (5). If filter is excessively clogged, flush
not on at 55% N2. system and check filter bypass valve for
operation (Ref. COM).
(5). Reinstall access covers and sound
insulation (Ref. Sec. 5240). (6). Install new filter element and new
Orings.
4. Main Transmission Filter Replacement
(369D25100 Transmission) (7). Install and tighten housing.
(1). Remove interior trim and blower access (8). If necessary, replenish transmission oil
door. supply; then perform ground runup of
helicopter and check split line for oil
(2). Position container or cloth to catch leakage.
residual oil. Loosen and remove filter
housing by turning counterclockwise. (9). Reinstall blower access door and
interior trim.
(3). Remove filter element.
6. Main Transmission Scavenge Pump
(4). Inspect filter element for metal par- Replacement (369F5100 Transmission)
ticles. If metal particles are present,
remove main transmission chip detec- (Ref. Figure 402)
tors and inspect for other evidence of
A. Main Transmission Scavenge Pump
internal failure in gearbox.
Removal (369F5100 Transmission)
(5). If filter is excessively clogged, flush
system and check filter bypass valve for (1). Remove sound insulation and transmis-
operation (Ref. COM). sion access covers (Ref. Sec. 5240).
(6). Install new filter element and new (2). Remove hardware that secure pump
Orings. housing to mounting pad.
(7). Install housing and torque to 70 100 (3). Remove pump and discard Orings.
inchpounds (7.91 11.30 Nm). B. Main Transmission Scavenge Pump
(8). If necessary, replenish transmission oil Installation (369F5100 Transmission)
supply; Then perform ground runup of
helicopter and check for oil leakage. Consumable Materials
(9). Reinstall, in order, blower access door Item Nomenclature
and interior trim.
CM114 Petrolatum
5. Main Transmission Filter Replacement
(369F5100 Transmission) (1). Install new Orings in ports and in
(1). Remove interior trim and blower access groove of pump sleeve. Apply light
door. coating of petrolatum (CM114) to both
(2). Position container or cloth to catch sion to prevent damage to Orings.
residual oil. Loosen and remove filter
housing by turning counterclockwise. (2). Align square drive of pump with drive
shaft in transmission and carefully
(3). Remove filter element. press pump into place.
(4). Inspect filter element for metal par- (3). Install attaching hardware; torque to
ticles. If metal particles are present, 40 50 inchpounds (4.52 5.65 Nm)
remove main transmission chip detec- plus drag torque.
Page 404
Revision 20 632100
MAINTENANCE MANUAL
(4). Ground run helicopter (Ref. PFM) and NOTE: MDHS Notice DN72.1 provides in-
check pump interface for leaks per structions for modifying oil cooler drain sys-
Fluid Leak Analysis (Ref. Sec. 6320). tem on early model helicopters to current
configuration.
7. Main Transmission Oil Cooler Bypass
(3). Remove oil drain tube and drain fitting.
Valve Replacement
(4). Detach oil cooler outlet duct.
(Ref. Figure 403) The oil cooler bypass valve
causes main transmission lubrication oil to (5). Remove compressor cooling duct and
bypass the oil cooler when oil temperature is pull oil cooler outlet duct away from oil
178 2F (82 1C) or less, or the following cooler.
conditions exist: pressure differential of 25 psi
(172 kPa) or higher across oil cooler with oil (6). Remove hardware that secures oil
temperature of 190F (88C) or higher. cooler and oil cooler inlet duct to
Excessive transmission oil temperature can be firewall; remove oil cooler.
caused by failure of oil cooler bypass valve to
seat in housing. Before installing new valve, (7). Remove covers from oil cooler by
inspect seat within housing. If housing seat is breaking lockwire and cutting sealant.
damaged, housing must also be replaced. NOTE: MDHS Notice DN23.2 contains infor-
mation relative to installation of oil cooling
Consumable Materials lines.
(Ref. Section 910000) B. Main Transmission Oil Cooler Installation
Item Nomenclature
Item Nomenclature
(1). Prepare container for draining oil from
transmission oil cooler lines upstream CM112 Antiseize compound high temperature
of bypass valve housing through bypass CM408 Adhesive, silicone rubber
valve port. Unscrew valve and drain oil CM702 Lockwire CRES
in container. Install an AN80612 plug CM715 Tape, pressure sensitive
in housing to eliminate residual drip.
(2). Apply light coat of antiseize compound (1). Scrape old sealant and remnants of
(CM112) to valve threads and install pressuresensitive tape seals from oil
Oring on valve. Torque valve to 50 cooler covers and reinstall covers with
60 inchpounds (5.65 6.78 Nm). (CM702) lockwire and sealant (CM408).
Use sealant to fill gaps (four places) at
(3). Replenish transmission oil lost during ends of covers.
bypass valve removal (Ref. Sec.
120000). (2). Make up four 0.125 inch (3.175 mm)
thick and four 0.250 inch (6.35 mm)
8. Main Transmission Oil Cooler thick seals, all 0.750 inch (19.05 mm)
Replacement wide, from pressuresensitive tape
(CM715).
A. Main Transmission Oil Cooler Removal (3). Apply seals, fabricated in previous step,
on oil cooler and oil cooler covers. Cut
(1). Drain main transmission lubrication holes in seals to accommodate bolts
system (Ref. Sec. 120000). (eight places).
(2). Remove two tubes that connect oil (4). Secure oil cooler and oil cooler inlet
cooler to oil cooler bypass valve hous- duct to firewall with four bolts, washers
ing. and nuts.
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632100 Revision 20
MAINTENANCE MANUAL
SEALANT
LOCKWIRE
SEALANT
COOLER COVER LOCKWIRE AND

SEALANT (TYPICAL BOTH ENDS)
OIL COOLER
OIL COOLER BYPASS
INLET DUCT
VALVE HOUSING
SEAL
0.125 X 0.50 X 7.06 IN. FIREWALL
(3.175 X 1.270 X 179.324 MM)
DOUBLER
OIL COOLER
ELBOW
TEE
DRAIN CAP DRAIN

FITTING
SEAL
0.125 X 0.50 X 5.90 IN.
(3.175 X 1.270 X 149.86 MM)
COMPRESSOR
COVER COOLING DUCT
(2 PLCS)
SEAL (4 PLCS) OIL COOLER

SEAL (4 PLCS)
0.125 X 0.75 X 5.25 IN. INLET DUCT
0.250 X 0.75 X 5.75 IN.
(6.35 X 19.05 X 146.05 MM) (3.175 X 19.05 X 133.35 MM) 632002A
Figure 403. Main Transmission Oil Cooler Installation
Page 406
Revision 20 632100
MAINTENANCE MANUAL
(5). Secure oil cooler outlet duct to oil cooler replenish transmission with oil lost
with four bolts, washers and nuts. (Ref. Sec. 120000).
(6). Install tee (with drain cap), elbow and 10. Main Transmission Oil Pressure Sender
tubes that run from oil cooler to oil Replacement
cooler bypass valve housing, applying
light coat of antiseize compound (Ref. Figure 404) The main transmission oil
(CM112) to threads. pressure sender provides a ground to cause the
XMSN OIL PRESS warning light to illumi-
(7). Install oil drain tube and fitting on tee. nate when oil Pressure is low. It also provides
a ground to the runningtime meter. Senders
(8). Install compressor cooling duct. normallyclosed contacts open when oil
pressure increases to 15 2 psi (103 14 kPa);
(9). Fill main transmission lubrication simultaneously the senders normallyopen
system (Ref. Sec. 120000). contacts close.
9. Main Transmission Oil Temperature Consumable Materials

Sender Replacement (Ref. Section 910000)
Item Nomenclature
(Ref. Figure 404) The oil temperature sender CM112 Antiseize compound high temperature
for the main transmission lubrication system
CM726 Tape, teflon
is installed in a housing inserted in the 1/2
inch oil line to IN port of lubrication pump.
Switch contacts close when oil temperature (1). Detach electrical wire or wires and
exceeds 240 l0F (116 5C). using absorbent cloth, unscrew sender
from transmission.
Consumable Materials (2). Apply light coat of antiseize compound
(Ref. Section 910000) (CM112) or wrap two or three turns of
Item Nomenclature teflon tape (CM726) on tapered threads
CM112 Antiseize compound high temperature of sender. Screw in sender; torque to 30
CM726 Tape, teflon 40 inchpounds (3.39 4.52 Nm).
Connect wire; make sure that connec-
tion is clean and tight. If three wires
(1). Remove lockwire and detach electrical are present, for information on connec-
wire from sender terminal post. tion of third wire refer to wiring
Position container for draining trans- diagram for running time meter.
mission oil cooler line. Remove two set
screws securing sender within sender 11. Liquid Level Plug Replacement
housing. Unscrew sender and drain oil
in container. Plug housing to prevent oil (1). Drain oil from transmission until oil
drainage. level is well below edge of plug port
(Ref. Sec. 120000).
(2). Apply a light coat of antiseize com-
(2). Remove safetywire from plug.
pound (CM112) or tightly wrap two or
three turns of teflon tape (CM726) on (3). Remove plug by unscrewing counter-
tapered threads of sender. Screw clockwise.
temperature sender into housing;
torque to 30 40 inchpounds (3.39 (4). Remove and discard Oring. Install
4.52 Nm). Install set screws until light new Oring on plug.
contact is made with sender. Lockwire
hex of sender to drilled head of ground (5). Install plug by screwing clockwise.
wire screw in sender housing. Connect Torque plug to 80 90 inchpounds
electrical wire to sender terminal and (9.04 10.17 Nm); install safetywire.
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632100 Revision 20
MAINTENANCE MANUAL
BREATHERFILLER
SPLINES FOR ORING
MAIN ROTOR (NOTE)
DRIVE SHAFT
OUTPUT SHAFT
(TAIL ROTOR)
OIL SEAL
OIL PRESSURE
SENDER
COOLING BLOWER
MOUNTING BRACKET
CHIP DETECTOR
AND SELFCLOSING
DRAIN VALVE
COOLING BLOWER
CHIP DETECTOR PULLEY SPACER
SELFCLOSING INPUT SHAFT

DRAIN VALVE
NOTE:
INPUT SHAFT SEAL
ORING MUST BE CEMENTED IN PLACE
DRAIN CONNECTOR
BEFORE INSTALLING TRANSMISSION. 632001
Figure 404. Main Transmission CrossSection View
12. Chip Detector Replacement belt. The blower exhausts air through the
(Ref. Figure 404) For removal and installation engine oil cooler and the main transmission oil
instructions, refer to Draining Main Transmis- cooler. Exhaust air from transmission and
sion (Ref. Sec. 120000). For functional test engine oil coolers is directed at various
information for detector circuit, refer to Sec. external portions of the engine and engine
953000. accessories.
B. Cooling Blower Removal
13. Cooling Blower Replacement (Ref. Figure 405)
A. Cooling Blower (1). Remove main transmission drive shaft
(Ref. Figure 405) The cooling blower is and blower access door.
mounted to a bracket on the aft underside of (2). Remove coupling bolt, coupling, shim(s)
the main transmission and coupled to the and pulley from transmission input
transmission input shaft by a pulleydriven shaft.
Page 408
Revision 42 632100
MAINTENANCE MANUAL
(3). Disconnect cooling blower drain tube. In the following step do not use
Loosen tiedown straps on blower duct CAUTION levers or other tools on belt, or
rubber connectors and roll back in any way force belt onto pulley.
connectors to disconnect ducts from
cooling blower. (5). Slide pulley onto transmission input
(4). Cut lockwire and remove four bolts shaft to engage belt in teeth of both
attaching mounting bracket to trans- pulleys.
mission. Remove two shims inserted (6). Adjust belt tension.
between bracket and transmission pad. NOTE: Instructions in step (7). below, apply
(5). Remove mounting bracket (with blower,
only when original shim(s) (same shim
pulley and belt) from helicopter.
thickness) are installed and drive shaft,
NOTE: For 369D25100 transmission installa- overrunning clutch and couplings remain
tion only; If equipped with 369D2562611
mount bracket, examine bolts securing unchanged. A distance of 0.010 inch (0.254
mount bracket to cooling blower assembly. If mm) between bolt seating surface on cou-
safety wired, remove and discard bolts. Re- pling and transmission input shaft is re-
place with NAS12241L selflocking bolts. quired to ensure coupling bolt will not bot-
tom out shaft and to provide proper
(6). Disassemble cooling blower if required.
assembly clamp up. (Ref. Sec. 631000).
C. Cooling Blower Installation (369D25100 The 0.010 inch (0.254 mm) mini-
Transmission) CAUTION mum measurement between the
(Ref. Figure 405) bolt seating surface and the input shaft
(1). Install pulley guard on main transmis- must be obtained to ensure proper clamp up.
sion input shaft. Warped shims or foreign material could pro-
(2). With belt looped around transmission vide a false 0.010 inch (0.254 mm) minimum
input shaft, position mounting bracket measurement and improper clamp up could
on main transmission pad and loosely result during normal operation which may
install four bolts and washers. Before damage the main transmission input shaft.
tightening bolts, insert two shims
between bracket and transmission pad. (7). Install laminated shim and coupling on
Verify that blower scroll clears tail rotor transmission input shaft. Secure
drive shaft by at least 0.190 inch (4.83 coupling with coupling bolt; torque to
mm). Torque bolts to 65 75 inch 250 300 inchpounds (28.25 33.90
pounds (7.34 8.47 Nm). Lockwire Nm) plus drag torque.
bolt heads after belt tension is checked.
(3). Connect drain tube to cooling blower (8). Make sure belt tracks correctly (Ref.
scroll fitting. Clamp tube to fitting with
Cooling Blower Belt Tracking).
two turns of lockwire.
(4). Roll exhaust duct rubber connectors (9). Install main transmission drive shaft
onto scroll outlets and secure with
(.Ref Sec. 631000).
tiedown straps (Transmission oil
cooler duct and engine oil cooler duct). (10). Install access panels.
Page 409
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MAINTENANCE MANUAL
TRANSMISSION
INPUT COUPLING INTERNAL
WRENCHING BOLT
MOUNTING
BRACKET
0.010 IN. (0.254 MM) MINIMUM
(BETWEEN END OF SHAFT AND
BOLT SEATING ON SURFACE
ON COUPLING)
SHIM
(TYP, 2 PLCS)
MAIN
TRANSMISSION
WASHER
DRIVEN
PULLEY FAN
MOUNTING ENGINE OIL RUBBER
BRACKET COOLER DUCT CONNECTOR
INPUT SHAFT TIE WRAP STRAP

(TYP)
COOLING
WASHER BLOWER
COOLING
BLOWER SPACER
PULLEY
SPACER
DRIVER PULLEY
LAMINATED
COUPLING SHIM
PULLEY GUARD
INTERNAL
WRENCHING BOLT
RUBBER
CONNECTOR
BELT
TRANSMISSION
INPUT COUPLING
G632000
Figure 405. Cooling Blower Installation (369D25100 Transmission)
Page 410
Revision 42 632100
MAINTENANCE MANUAL
D. Cooling Blower Installation (369F5100 In the following step, do not use

Transmission) CAUTION levers or other tools on belt, or
in any way force belt onto pulley.
(Ref. Figure 406)
(6). Slide driver pulley onto transmission
Consumable Materials input shaft to engage belt in teeth of
(Ref. Section 910000) both pulleys.
Item Nomenclature
The minimum of 0.010 inch
CM111 Grease, aircraft CAUTION (0.254 mm) measurement be-
CM425 Sealing compound tween the bolt seating surface and the input
CM702 Lockwire CRES shaft must be obtained to ensure proper
clampup.
(1). With belt looped around driven pulley, D Warped shims or foreign material could
install oil cooler fan bracket. provide a false 0.010 inch (0.254 mm)
minimum measurement and improper
NOTE: NAS1304 series bolts may be used in clampup could result, which during nor-
place of NAS6604 series bolts. mal operation, may damage the main
(a). Install four bolts with washers transmission input shaft.
through oil cooler mounting bracket D Do not use clutch coupling shims under
into fan bracket. transmission input coupling. Inside diam-
(b). Before tightening bolts, displace eter of clutch coupling shim is different
cooler toward the transmission flange than shim used on transmission input
coupling. Incorrect diameters can cause
to eliminate slack in that direction.
an improperly seated shim, misalignment
(c). Torque bolts to 70 90 inchpounds
and cocked coupling.
(7.91 10.17 Nm) and safety with
(7). Torque bolts to 70 90 inchpounds
lockwire (CM702).
(7.91 10.17 Nm).
(d). After bolts are torqued, seal around (8). Coat threads of coupling bolt with
bolt heads with sealant (CM425). antiseize compound (CM112).
(9). Lubricate input shaft splines and
When installing pulley and
CAUTION guard, make sure the spring pin
coupling splines with grease (CM111).
(10). Install input coupling shim and
in pulley is fully engaged inside hole in coupling on transmission input shaft
pulley guard. If the spring pin does not align with coupling bolt.
correctly with hole in pully guard, the (11). Adjust belt tension (Ref. Cooling Blower
torque will be incorrect. Belt Tension Check and Adjustment).
NOTE: Check coupling bolt for a minimum of
(2). Install pulley guard on main transmis- 25 inchpounds (2.82 Nm) drag torque.
sion input shaft. (12). Torque coupling bolt to 315 365
(3). With belt looped around transmission inchpounds (35.59 41.24 Nm) plus
input shaft, position mounting bracket drag torque.
on main transmission pad and loosely (13). 369D, E, F, and 500N Make sure belt
install two bolts with washers from the tracks correctly (Ref. Cooling Blower
bottom of bracket and two bolts with Belt Tracking).
washers from top of bracket. (14). Connect drain tube to cooling blower
(4). Before tightening bolts, insert two scroll fitting. Clamp tube to fitting with
shims between bracket and transmis- two turns of lockwire (CM702).
sion pad. (15). Roll exhaust duct rubber connectors
(5). Verify that blower scroll clears anti onto scroll outlets (transmission oil
torque drive shaft by a minimum of cooler duct and engine oil cooler duct)
0.190 inch (4.826 mm). and secure with tie straps.
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632100 Revision 43
MAINTENANCE MANUAL
BOLT
BOLT
OIL COOLER FAN

BRACKET FAN BRACKET
BOLT
SHIM
BOLT
PULLEY GUARD
TRANSMISSION INTERNAL
INPUT COUPLING WRENCHING BOLT
INPUT COUPLING
DRIVER PULLEY
BOLT
INPUT COUPLING SHIM

0.010 IN. (0.254 MM) MINIMUM
(BETWEEN END OF SHAFT AND BOLT
SEATING ON SURFACE ON COUPLING)
CSP102012D
Figure 406. Oil Cooler Blower Installation (369F5100 Transmission)
Page 412
Revision 42 632100
MAINTENANCE MANUAL
E. 369D, E, F, and 500N Cooling Blower (3). Rotate the lower driver pulley by hand
Belt Tracking in a counterclockwise direction. Make
(Ref. Figure 407) sure the belt tracks axially towards the
blower on the upper driven pulley.
(1). Make sure the oil cooler belt tracks
correctly. (4). If the oil cooler belt does not track
(2). Rotate the lower driver pulley with correctly, replace with a serviceable
your hand in a clockwise direction (as belt.
you look at the main rotor transmission
input). Make sure the belt tracks
axially away from the blower on the
upper driven pulley.
BLOWER
DRIVEN PULLEY
NOTE 1
DRIVEN PULLEY
NOTE 2
DRIVER PULLEY
(NOTES 1,2)
NOTES; MAIN TRANSMISSION
DRIVE SHAFT
1. TURN DRIVER PULLEY CLOCKWISE.
VERIFY BELT TRACKS AWAY FROM BLOWER.
2. TURN DRIVER PULLEY COUNTERCLOCKWISE.
VERIFY BELT TRACKS TOWARDS BLOWER. 632034
Figure 407. Cooling Blower Belt Tracking
Page 413
632100 Revision 43
MAINTENANCE MANUAL
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Revision 42 632100
MAINTENANCE MANUAL

AND COOLING SYSTEM
INSPECTION/CHECK
1. Lubrication System Inspection (4). Examine scroll for cracks or breaks,
and for secure attachment to hub.
(Ref. Figure 601)
(5). Examine rubber connectors at engine
(1). Inspect plumbing and system compo- oil cooler duct and transmission oil
nents from oil cooler to lubrication cooler duct where they attach to scroll.
pump for leaks, secure attachment and Examine ducts for damage.
damage.
(6). Look through hub support legs and, to
(2). Inspect oil cooler, lubrication pump, oil extent possible, inspect impeller for
filter, oil pressure switch, liquid level damage. A crack, loose rivet or dis-
plug, and chip detectors for leaks, torted vane is cause for impeller
secure attachment and damage. replacement. Inspect mount screws and
bolts for evidence of broken slippage
(3). Inspect electrical connections at oil mark paint.
temperature switch, oil pressure
switch, and chip detectors for absence (7). Examine scroll drain tube for damage,
of corrosion, secure attachment and secure attachment and clear passage.
damage.
(8). Examine mounting bracket and fan
2. Cooling Blower Inspection mounting bracket for secure attach-
ment. Check for broken lockwire at bolt
(Ref. Figure 405) heads securing mounting bracket
cooling blower assembly.
(1). Remove blower access door and inspect
belt for damage or excessive wear. Belt 3. Cooling Blower Inspection
should be fully seated in pulley grooves. (Disassembled)
Limited cracking or separation of belt.
(a). Belt should be fully seated in pulley
grooves.
Item Nomenclature
(b). Limited cracking or separation of belt CM206 Chemical coating
between pulley grooves is acceptable. CM318 Primer
Visually monitor any propagation. CM801 Abrasive paper, silicon carbide
Belt should be replaced if any one
separation exceeds three inches in
length or if total separation exceeds (1). Examine belt for damage or excessive
50 percent of peripheral length of wear (Ref. Figure 405).
belt. (For belt replacement schedule,
refer to Section 051000). (2). Examine driver pulley, spring pin,
pulley guard and driven pulley for
(2). Check belt tension. damage or excessive wear.
(3). Handrotate main rotor to examine all (3). Check driven pulley retaining nut for a
visible areas of driven pulley and driver minimum of 160 inchpounds (18.08
pulley for damage or excessive wear. Nm) plus drag torque. If loss of
Listen for sounds of defective bearings torque is indicated, remove pulley nut
or of impeller touching scroll while and inspect washer for evidence of
rotor is turned. elongation and wear.
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MAINTENANCE MANUAL
OIL PRESSURE
SENDER
LUBRICATION PUMP
MAIN TRANSMISSION AND OIL FILTER
OIL TEMPERATURE
SENDER
GROUND WIRE
OIL COOLER
BYPASS VALVE
CHIP DETECTORS
OIL COOLER BLOWER
TRANSMISSION OIL
COOLER DUCTS
OIL COOLER
OIL LEVEL PLUG
VIEWED FROM RH SIDE OF

MAIN TRANSMISSION
NOTE 1
NOTE: DRAIN CAP

DRAIN CAP INSTALLED AT THIS LOCATION
(EARLY CONFIGURATION ONLY) G632007A
Figure 601. Main Transmission Cooling Blower and Duct

(4). Check pulley shaft and splines for (7). Examine scroll (Ref. Figure 801) for
condition. Replace damaged flat washer cracks, breaks and distortion.
or ring washer with flat washer. Install
and torque nut to 160 190 inch Handle impeller carefully to
CAUTION prevent damage that could
pounds (18.08 21.47 Nm) plus drag
torque. cause imbalance and require replacement of
impeller.
(5). Examine mounting bracket and fan
mounting bracket for cracks and (8). Visually (minimum 10X magnification)
breaks. examine impeller (Ref. Figure 801) for
cracks, deformation and separation.
(6). Examine web of mounting bracket for
(a). Look for foreign material attached to
wear.
impeller. None is permitted.
(a). Remove nicks, scratches or grooves (b). Check for loose rivets at hub.
leaving sharp impressions in web.
Minimum acceptable web thickness: (c). Use electroprobe or gage of equiva-
0.125 inch (3.175 mm). lent accuracy to measure depth of
scratches or nicks.
(b). Replace mounting bracket if web does
not meet 0.125 inch (3.175 mm) (d). Use penetrating dye to examine
minimum after repair. suspected cracks.
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Revision 36 632100
MAINTENANCE MANUAL
(e). Scratches and nicks not exceeding Kg). This load is to be applied at a right
0.006 inch (0.152 mm) depth are angle to the outside face of the belt.
repairable by sanding with grade 320 Measure belt deflection without turning
abrasive paper (CM801) to blend driven pulley, then turn driven pulley
defect into surrounding area. 1/2 turn and repeat belt deflection
measurement. Turn driven pulley an
1). Treat blended areas with chemical additional 1/4 turn and measure belt
coating (CM206) and touchup deflection again.
with primer (CM318).
(a). If the tension is too high, greater
2). All other defects require replace- than 2.00 pounds (0.9072 Kg),
ment of impeller. tension can be reduced by peeling off
(9). Examine shaft for damage or excessive a layer of the laminated shim, one at
wear. Discard seal (Ref. Figure 801). a time equally from both shims, until
tension falls into proper range.
4. Cooling Blower Belt Tension Check and (b). If the tension is too low: Add layers
Adjustment from a spare shim in the same
(1). Check that laminated shims are in manner as removed in step (2).(a).
position between mounting bracket and above, until tension falls into proper
transmission fan mount assembly. range.
Tighten the four mounting bolts. Rotate (3). Make a final check of bolt torque:
pulley by hand a few turns to even out
belt tension. For 369D25100 transmission installa-
tion, 65 75 inchpounds (7.34 8.47
(2). Measure belt deflection three times at Nm), and then lockwire drilled heads.
approximate center of one of the spans.
The force required to deflect the belt For 369F5100 transmission installa-
0.1700.200 inch (4.325.08 mm) must tion, 70 90 inchpounds (7.91
be 1.752.00 pounds (0.79380.9072 10.17 Nm).
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632100 Revision 37
MAINTENANCE MANUAL
Page 604
Revision 36 632100
MAINTENANCE MANUAL

AND COOLING SYSTEM
REPAIRS
1. 369D25630 Cooling Blower Disassembly holding device meeting requirements of
caution above, and remove impeller
(Ref. Figure 801) retaining nut and washer.
NOTE: Disassemble cooling blower only to ex- Be careful to prevent impeller
tent necessary to perform inspection, re- CAUTION damage. Slight impeller defor-
placement or repair of specific items. Re- mation or damage can cause imbalance.
place cooling blower bearings and belt per Protect shaft threads and use nonmetallic
replacement schedule (Ref. Sec. 051000). mallet when performing step (8). below.
Bolts used to secure mount bracket to cool-
ing blower must be selflocking type only. (8). Manually support impeller and sepa-
Discard bolts if safety wired and replace rate impeller from shaft by carefully
with selflocking bolts (Ref. Figure 405). tapping end of shaft. Remove impeller,
scroll, key, spacer and any shimming
(1). Remove mounting bracket (Ref. Sec. present.
632000).
(9). Remove bolt, retaining ring and spring
(2). Remove scroll cover. washer from hub.
(3). Hold impeller retaining nut with socket (10). Use nonmetallic mallet on splined end
wrench and remove drivenpulley of shaft to drive impellerend bearing,
retaining nut and washer. seal, and portion of the shaft from hub.
Do not attempt to remove sleeves from
(4). Remove driven pulley. Do not forcefully hub. Sleeves are linereamed. If either
tap or pry; if necessary, use pulling sleeve is defective, hub must be re-
device. placed. Remove inner retaining ring
from hub. Remove and discard Oring
(5). Remove spacer from impeller shaft. in upper sleeve if installed.
(6). Remove four screws and washers that (11). If necessary, use pulling device to
attach scroll to hub. extract bearing and seal from shaft.
In following step, do not use (12). If remaining bearing cannot be driven
CAUTION tools or other devices to hold im- from hub by tapping outer race from
peller. Tool damage can affect impeller bal- inside with nonferrous tube and mallet,
ance. Holding device must not damage shaft reinsert shaft into bearing, drive
splines and must hold shaft with 250 300 bearing out and remove it from shaft as
inchpounds (28.25 33.90 Nm) of torque described in steps (10). and (11). above.
applied to impeller retaining nut.
(13). Discard bearings. They are not to be
(7). Secure splined end of impeller shaft in reused.
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632100 Revision 22
MAINTENANCE MANUAL
SHAFT
SLEEVE
HUB BEARING (NOTE 1)
ORING
SHAFT
BEARING SLEEVE
(NOTE 2)
HUB INNER RETAINER
RING
CAVITY FILLED
MINIMUM CLEARANCE WITH GREASE
SCREWS AND WASHERS
TO PREVENT RUBBING (4 PLCS)
(NOTE 3) BOLT
SEAL (PART
BEARING
OF BEARING) BLOWER
SCROLL
SLEEVE
SEAL
IMPELLER
SCREW AND WASHER (8
PLCS)
SPRING WASHER WASHER KEY NUT

SEALANT COVER
OUTER RETAINING RING LAMINATED (NOTE 1)
SHIM
DRAIN TUBE
OUTLET
COVER
(NOTE 2)
NOTES:
1. CURRENT CONFIGURATION.
2. EARLY CONFIGURATION.
G6320091
3. CLEARANCE SHALL BE 0.0200.040 IN. (0.5081.016 MM) MINIMUM.
Figure 801. 369D25630 Cooling Blower CrossSection View
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Revision 22 632100
MAINTENANCE MANUAL
2. 369D25630 Cooling Blower Reassembly (7). Lightly grease (CM116) larger bearing
journal of shaft and bore of remaining
(Ref. Figure 801) bearing.
On current configuration Cool-
Consumable Materials CAUTION ing blowers, apply locking com-
(Ref. Section 910000) pound (CM431) to outer race of lower bear-
Item Nomenclature ing (impeller end) only. Do not apply locking
CM116 Grease, aircraft and instrument compound to upper bearing (pulley end).
(8). Apply primer (CM321) and locking
CM220 Naphtha aliphatic compound (CM431) to faying surfaces of
CM222 1,1,1Trichloroethane outer bearing race and sleeve according
CM321 Surface primer locking compound to container instructions. Be careful to
CM425 Sealing compound prevent compounds from entering
CM431 Sealing, locking and retaining compound bearing.
NOTE: On newer style bearings, the metal
NOTE: Following procedure covers assembly of shield is replaced by a blue shield.
completely disassembled cooling blower, to- (9). Insert bearing so that shield side (metal
gether with those items (belt, brackets, etc) shield or blue disc) faces interior of hub
that form a complete unit. Use only applica- and seal side (rubber disc) faces
ble steps of procedure when disassembly is impeller end of shaft.
less than complete. New bearings and new
seal are required; those removed are not to (10). Arborpress bearing simultaneously
be reused. onto shaft journal and into sleeve.
Exert pressure equally on both races of
(1). Install inner retaining ring in hub and bearing. At same time, exert equal
if removed at disassembly install new pressure on splined end of shaft and
Oring in upper bearing sleeve. pulley end of hub casting. Bearing is to
firmly contact shaft shoulder and inner
(2). Lightly grease (CM116) smaller bearing retaining ring.
journal of shaft, and bore of correspond-
ing bearing. MEK solvent is flammable.
WARNING Use only in wellventilated
NOTE: This bearing does not have a metal area and away from heat and flame.
shield.
(11). Wipe away excess locking compound.
(3). Place bearing on shaft so that rubber Use methyl ethyl keytone (CM219) if
seal of bearing faces splined end of hardening begins. Leave assembled
shaft. parts undisturbed to permit locking
compound to cure for two hours at
(4). Using tube that contacts only edge of
75100F (2438C), or for ten
inner race of bearing, arborpress
minutes at 220 l0F (105 5C).
bearing onto journal until inner race
contacts shaft shoulder. (12). Temporarily install lubrication fitting.
(5). Clean outer race of both bearings and (13). Install new seal, spring washer and
faying surfaces of both hub sleeves with outer retaining ring.
trichloroethane (CM222) and clean
cloth or paper towel. (14). Fill hub cavity with grease (CM116)
through lubrication fitting until grease
(6). Arborpress bearing (with shaft seeps out around seal of bearing
installed) into sleeve. Exert pressure nearest splined end of shaft. After
only on bearing outer race and on lubrication, remove lubrication fitting
impellerend of hub casting (no and install screw and washer. Lockwire
pressure on impellerend sleeve). screwhead.
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MAINTENANCE MANUAL
(15). Install hub on scroll with four screws tightening bolts, fully displace bracket
and washers. Torque screws to 12 15 in direction that causes it to be closest
inchpounds (1.36 1.69 Nm). to main transmission drive shaft when
cooling blower is installed, then torque
(16). Install spacer and impeller on shaft. bolts to 65 75 inchpounds (7.34
8.47 Nm). Apply slippage mark paint.
(17). Install washer and locknut on end of
shaft. Using holding device on splined (23). (Ref. Figure 405) Install spacer, washer,
end of shaft, tighten locknut sufficiently pulley, washer and nut on shaft. Hold
to remove all end clearance from nut on impeller end of shaft with socket
stackup of parts. wrench and tighten pulley nut to 160
190 inchpounds (18.08 21.47 Nm)
(18). Using feeler gage through an air outlet plus drag torque.
port, measure minimum clearance
between impeller and scroll lip. (24). (Ref. Figure 405) Install belt on pulley
and secure mounting bracket to fan
NOTE: If minimum clearance is 0.0200.040 mounting bracket with four bolts and
inch (0.5081.016 mm), steps (19). and (20). washers. Before tightening bolts, fully
below may be bypassed. displace bracket in direction that
causes it to be closest to main transmis-
(19). If clearance is more than 0.040 inch sion drive shaft when cooling blower is
(1.016 mm), remove impeller and installed, then torque bolts to 65 75
spacer. Replace spacer with 369H5654 inchpounds (7.34 8.47 Nm) and
shims as required between impeller and lockwire drilled heads.
seal to obtain 0.0200.040 inch
(0.5081.016 mm) clearance. Reinstall (25). Clean faying surfaces of scroll and
impeller, washer and locknut. Tighten cover with naphtha (CM220); apply
to remove all end clearance, and then sealant (CM425) according to container
rotate impeller and check for rubbing. If instructions before securing cover to
rubbing occurs, perform step (20)., scroll with eight screws and washers.
otherwise proceed to step (21)..
3. 600N5630 Cooling Blower Disassembly
(20). If clearance is less than 0.020 inch (Ref. Figure 802)
(0.508 mm), or if rubbing occurs when
performing previous step, disassemble NOTE: Disassemble cooling blower only to ex-
and install shim(s) between seal and tent necessary to perform inspection, re-
spacer to ensure 0.0200.040 inch placement or repair of specific items. Re-
(0.5081.016 mm) minimum clearance place cooling blower bearings and belt per
and prevent rubbing. replacement schedule (Ref. Sec. 051000).
(21). When clearance is properly adjusted, (1). Remove mounting bracket (Ref. Sec.
remove impeller, install key, impeller, 632025).
washer and locknut. Torque locknut to (2). Hold impeller retaining nut with socket
250 300 inchpounds (28.25 33.90 wrench and remove drivenpulley
Nm). Use care to avoid placing stress retaining nut and washer.
on impeller or scroll. Hold splined end
of shaft in suitable device. (3). Remove driven pulley. Do not forcefully
tap or pry; if necessary, use pulling
NOTE: Install two selflocking bolts in place of device.
safetywired bolts if not previously in-
stalled. (4). Remove spacer from impeller shaft.
(5). Remove two screws and washers that
(22). (Ref. Figure 405) Secure fan mounting attach scroll to shroud.
bracket on hub with four bolts and
washers on early configurations, or two (6). Remove four screws six washers, and
selflocking bolts, two screws and four two nuts that attach hub to shroud and
washers on current versions. Before scroll. Retain shim if installed.
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Revision 36 632100
MAINTENANCE MANUAL
SCREW
WASHER
SHROUD
NUT
WASHER
SHAFT
BEARING
HUB SCREW
SCREW WASHER
WASHER LOCKWIRE
ORING
SCROLL RETAINING RING
SHIM SHIM
(NOTE 3) (NOTE 3)
BEARING
SPRING
SEAL
WASHER
(NOTE 2)
NOTE 3
IMPELLER
RETAINING RING SHIM NUT WASHER

(NOTE 1) WOODRUFF KEY
NOTE:
1. SHIM IMPELLER TO PROVIDE 0.0200.030 IN. (0.5080.762 MM) AVERAGE BLADE
TRAILING EDGE TIP CLEARANCETOSHROUD, MEASURED PERPENDICULARLY TO
THE SHROUD FACE. THE BLADE TRAILING EDGE IS AT THE LARGEST BLADE
DIAMETER. SHIM PRIOR TO INSTALLING SCROLL.
2. INSTALL SEAL WITH SMALL DIAMETER GAP IN RINGS FACING OUTSIDE OF HUB.
3. SHIM HUB TO PROVIDE 0.020 IN. (0.508 MM) MINIMUM GAP BETWEEN SCROLL
G6320092A
AND IMPELLER.
Figure 802. 600N5630 Cooling Blower CrossSection View
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632100 Revision 36
MAINTENANCE MANUAL
In following step, do not use 4. 600N5630 Cooling Blower Reassembly

CAUTION tools or other devices to hold im-
peller. Tool damage can affect impeller bal- (Ref. Figure 802)
ance. Holding device must not damage shaft
splines and must hold shaft with 250 300 Consumable Materials
inchpounds (28.25 33.90 Nm) of torque (Ref. Section 910000)
applied to impeller retaining nut. Item Nomenclature
CM116 Grease, aircraft and instrument
(7). Secure splined end of impeller shaft in CM219 Methylethylketone
holding device meeting requirements of CM220 Naphtha aliphatic
caution above, and remove impeller
retaining nut and washer.
CM321 Surface primer locking compound
Be careful to prevent impeller
CAUTION damage. Slight impeller defor-
mation or damage can cause imbalance.
Protect shaft threads and use nonmetallic NOTE: Following procedure covers assembly of
mallet when performing step (8). below. completely disassembled cooling blower, to-
gether with those items (belt, brackets, etc)
(8). Manually support impeller and sepa- that form a complete unit. Use only applica-
rate impeller from shaft by carefully ble steps of procedure when disassembly is
tapping end of shaft. Remove impeller, less than complete. New bearings and new
scroll, key, spacer and any shimming seal are required; those removed are not to
present. be reused.
(1). Install inner retaining ring in hub and
(9). Remove bolt, retaining ring and spring if removed at disassembly install new
washer from hub and shroud. Oring in upper bearing sleeve.
(2). Lightly grease (CM116) smaller bearing
(10). Use nonmetallic mallet on splined end journal of shaft, and bore of correspond-
of shaft to drive impellerend bearing, ing bearing.
seal, and portion of the shaft from hub.
Do not attempt to remove sleeves from NOTE: This bearing does not have a metal
hub. Sleeves are linereamed. If either shield.
sleeve is defective, hub must be re-
(3). Place bearing on shaft so that rubber
placed. Remove inner retaining ring
seal of bearing faces splined end of
from hub. Remove and discard Oring
shaft.
in upper sleeve if installed.
(4). Using tube that contacts only edge of
(11). If necessary, use pulling device to inner race of bearing, arborpress
extract bearing and seal from shaft. bearing onto journal until inner race
contacts shaft shoulder.
(12). If remaining bearing cannot be driven (5). Clean outer race of both bearings and
from hub by tapping outer race from faying surfaces of both hub sleeves with
inside with nonferrous tube and mallet, trichloroethane (CM222) and clean
reinsert shaft into bearing, drive cloth or paper towel.
bearing out and remove it from shaft as
described in steps (10). and (11). above. (6). Arborpress bearing (with shaft
installed) into sleeve. Exert pressure
only on bearing outer race and on
(13). Discard bearings. They are not to be impellerend of hub casting (no
reused. pressure on impellerend sleeve).
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MAINTENANCE MANUAL
(7). Lightly grease (CM116) larger bearing (15). Install shim on scroll.
journal of shaft and bore of remaining
bearing. (16). Install hub and shroud on scroll with
six screws, eight washers and two nuts.
Apply locking compound Torque screws to 12 15 inchpounds
CAUTION (CM431) to outer race of lower (1.36 1.69 Nm).
bearing (impeller end) only. Do not apply (17). Using feeler gage through an air outlet
locking compound to upper bearing (pulley port, measure for 0.020 inch (0.508 mm)
end). minimum gap between impeller and
(8). Apply primer (CM321) and locking scroll.
compound (CM431) to faying surfaces of (18). Check for proper thread protrusion of
outer bearing race and sleeve according six screws through nutplates and nuts
to container instructions. Be careful to on inside of scroll.
prevent compounds from entering
bearing. (19). Install spacer and impeller on shaft.
(9). Insert bearing so that shield side (metal (20). Install washer and locknut on end of
disc) faces interior of hub and seal side shaft. Using holding device on splined
(rubber disc) faces impeller end of shaft. end of shaft, tighten locknut sufficiently
to remove all end clearance from
(10). Arborpress bearing simultaneously stackup of parts.
onto shaft journal and into sleeve. (21). Using feeler gage through an air outlet
Exert pressure equally on both races of port, measure minimum clearance
bearing. At same time, exert equal between impeller and scroll lip.
pressure on splined end of shaft and
pulley end of hub casting. Bearing is to NOTE: If minimum clearance is 0.0200.030
firmly contact shaft shoulder and inner inch (0.5080.762 mm), steps (19). and (20).
retaining ring. below may be bypassed.
MEK solvent is flammable. (22). If clearance is more than 0.030 inch
WARNING Use only in wellventilated (0.762 mm), remove impeller and
area and away from heat and flame. spacer. Replace spacer with 369H5654
shims as required between impeller and
(11). Wipe away excess locking compound. seal to obtain 0.0200.030 inch
Use methyl ethyl keytone (CM219) if (0.5080.762 mm) clearance. Reinstall
hardening begins. Leave assembled impeller, washer and locknut. Tighten
parts undisturbed to permit locking to remove all end clearance, and then
compound to cure for two hours at rotate impeller and check for rubbing. If
75100F (2438C), or for ten rubbing occurs, perform step (20).,
minutes at 220 l0F (105 5C). otherwise proceed to step (21)..
(12). Temporarily install lubrication fitting. (23). If clearance is less than 0.020 inch
(0.508 mm), or if rubbing occurs when
NOTE: Install seal with small diameter gap in performing previous step, disassemble
rings facing outside of hub. and install shim(s) between seal and
spacer to ensure 0.0200.030 inch
(13). Install new seal, spring washer and (0.5080.762 mm) minimum clearance
outer retaining ring. and prevent rubbing.
(14). Fill hub cavity with grease (CM116) (24). When clearance is properly adjusted,
through lubrication fitting until grease remove impeller, install key, impeller,
seeps out around seal of bearing washer and locknut. Torque locknut to
nearest splined end of shaft. After 250 300 inchpounds (28.25 33.90
lubrication, remove lubrication fitting Nm). Use care to avoid placing stress
and install screw and washer. Lockwire on impeller or scroll. Hold splined end
screwhead. of shaft in suitable device.
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MAINTENANCE MANUAL
(25). (Ref. Figure 406) Secure fan mounting 6. Transmission and Cooling Blower Drain
bracket on hub with two selflocking Tube Repair and Replacement
bolts, two screws and four washers.
Before tightening bolts, fully displace Consumable Materials
bracket in direction that causes it to be (Ref. Section 910000)
closest to main transmission drive shaft Item Nomenclature
when cooling blower is installed, then
CM702 Lockwire CRES
torque bolts to 50 70 inchpounds
(5.65 7.91 Nm) and screws to 65 75 CM717 Tape, pressure sensitive
inchpounds (7.34 8.47 Nm). Apply
slippage mark paint. (1). Disconnect drain tubes from transmis-
sion cooling blower, and from drain
fittings and weld assemblies at firewall.
(26). (Ref. Figure 406) Install spacer, washer, Release supporting nylon straps and
pulley, washer and nut on shaft. Hold remove drain tubes (Ref. Figure 601).
nut on impeller end of shaft with socket
wrench and tighten pulley nut to 160 (2). Inspect drain tubes, drain fittings, weld
190 inchpounds (18.08 21.47 Nm) assemblies and connectors for damage
plus drag torque. and clear passage.
(3). Repair damaged flexible drain tubes
with tape (CM716).
(27). (Ref. Figure 406) Install belt on pulley
and secure mounting bracket to fan (4). Install drain tubes as follows:
mounting bracket with four bolts and (a). Attach upper ends of drain tubes to
washers. Before tightening bolts, fully transmission and cooling blower.
displace bracket in direction that Secure with double wraps of lockwire
causes it to be closest to main transmis- (CM702).
sion drive shaft when cooling blower is
installed, then torque bolts to 65 75 (b). Route drain tubes and secure with
inchpounds (7.34 8.47 Nm) and nylon straps. Position tubes so that
lockwire drilled heads. no drainage traps are formed.
(c). Secure lower ends of drain tubes to
fittings and weld assemblies with
(28). Clean faying surfaces of scroll and
double wraps lockwire (CM702).
cover with naphtha (CM220); apply
sealant (CM425) according to container (d). Insert lower end of metal drain tube
instructions before securing cover to through grommet in skin and slip
scroll with eight screws and washers. upper end of tube into weld assembly.
Wrap tube with one layer of 1 inch
(2.54 cm) wide tape (CM717) at
5. Cooling Blower Cleaning (Disassembled) clampattach point, and install
clamp.
7. Installation of Heating System and Oil
Consumable Materials Cooling Line Standoff Clamps (0003D
(Ref. Section 910000) 0539D)
Item Nomenclature
(Ref. Figure 803) The following information
CM234 Solvent, drycleaning list a procedure for installing standoff clamps
on the 369D292490 heating system hose and
on the 369D25710 main rotor transmission oil
cooling line to eliminate chafing between the
(1). Clean all usable metal parts with oil cooling lines and chafing of the oil cooling
solvent spray (CM234). Remove lines by the heating system hose. A protective
remnants of locking compound with bushing is also installed to prevent chafing
loctite remover (CM216). between the oil cooling lines.
Page 808
Revision 36 632100
MAINTENANCE MANUAL
(1). Remove aft compartment interior trim (4). Check installation of standoff clamps to
panels and left Sta. 124.00 bulkhead ensure adequate clearance between
access door to gain access to work area. 369D25709 and 369D25710 oil cooling
lines and between oil cooling lines and
NOTE: Inspect the 369D292490 heating sys- 369D292490 heating system hose.
tem hose and 369D25709 and 369D25710
main transmission oil cooling lines for evi- NOTE:
dence of chafing, kinking or damage at area
of L/H aft section channel assembly. D Later Model 369D helicopters have
369D265443 closure plate (with grom-
(2). If not already installed, install met) installed on L/H aft section channel.
NAS1713D30N clamp on heating Remove plate from channel, if presently
system hose and NAS1713D8N clamp installed, to preclude interference with oil
on 369D25710 oil cooling line. Connect cooling lines.
clamps with screw, washer and nut.
D Later model 500D helicopters have
(3). If not already installed, install new HS41946 standoff bracket installed on
CSB168 bushing snug against nut channel with MS21919DG30 clamp to se-
on 369D25709 oil cooling tube assembly cure heating hose. Install standoff brack-
(View AA). Reposition clamp assembly et and clamp, if not presently installed on
securing 369D25709 (lower) and helicopter.
369D25710 (upper) oil cooling tube
assemblies to accommodate installation (5). Reinstall bulkhead access door and
of bushing. interior trim panels.
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632100 Revision 36
MAINTENANCE MANUAL
CLAMP ASSY
369D25710 OIL COOLING (RELOCATED)
TUBE ASSY
369D265443 CLOSURE PLATE

(REMOVE IF PRESENTLY INSTALLED
ON AFT SECTION CHANNEL)
(ROTATED)
369D25709 OIL COOLING

TUBE ASSY
VIEW AA
C5B168 BUSHING
(NOTE 3)
369D25710 OIL COOLING A
HS41946 STANDOFF (NOTE 1)
TUBE ASSY (REF)
MS20470AD3 RIVET (2)
C5B168 BUSHING
369D23024 AFT SECTION
CHANNEL ASSY
(CANT. STA. 124.00)
TUBE ASSY
A
NAS1713D8N CLAMP (NOTE 2)
NAS10967 SCREW
AN960PD10L WASHER (2) MS21919DG30 CLAMP (NOTE 1)
MS210433 NUT NAS109637 SCREW
AN960PD10L WASHER
TUBE ASSY
NAS1713D8N CLAMP (EXISTING)
AN74312 BRACKET 369D292490 HEATING HOSE
NAS109637 SCREW (2)
MS210433 NUT (3)
AN960PD10L WASHER (4) NAS1713D30N CLAMP
NAS1713D30N CLAMP (NOTE 2)
(EXISTING)
NOTES:
1. PRESENTLY INSTALLED ON LATEMODEL HELICOPTERS.
2. LOCATE NEW CLAMPS APPROXIMATELY AS SHOWN ON
COOLING TUBE AND HEATING HOSE ASSEMBLIES.
3. AFTER INSTALLATION OF BUSHING, ROTATE BUSHING SO G632026A
THAT SPLIT IN BUSHING IS FACING DOWN.
Figure 803. Installation of Standoff Clamps Heating and Oil Cooling Lines
Page 810
Revision 22 632100
MAINTENANCE MANUAL
Section
632200
Rotor Brake
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
ROTOR BRAKE
When working with hydrau- pressure is produced; this pressure is trans-
WARNING lic systems, special care mitted through the tubing to the caliper
must be taken to prevent entrance of assembly where it acts on the pistons. This
dust, moisture or other foreign materi- causes the pucks to apply clamping pressure
al. System contamination can cause (braking force) to the brake disc. System
malfunctions which could cause injury pressure is held within safe limits, regardless
to personnel or equipment damage. of the force applied to the brake handle, by
operation of the pressurerelief valve. When
1. Rotor Brake hydraulic pressure exceeds 500 psig (3447
kPa), the pressurerelief valve opens, venting
The rotor brake enables the pilot to manually excess pressure back to the master cylinder.
brake the rotor system to a stop by operating a When application of force is discontinued,
single brake handle. The handle is installed on caliper pistons (and the pucks) are retracted
the upper left (or upper right, depending on by return springs in the caliper assembly.
helicopter seating configuration) side of the Pucktodisc clearance is maintained by
canted bulkhead 78.50 control tunnel in the action of a selfadjusting mechanism in the
pilots compartment. Operation of the brake caliper assembly. The original equipment
handle actuates a master cylinder, causing tachometer generator is replaced by a new unit
dual pucks to grip a brake disc installed on the that is included in the rotor brake installation
tail rotor drive shaft. Braking force is trans- to provide clearance between the tachometer
mitted through the main transmission to the generator and the brake disc. The original
main rotor. A friction clip secures the handle in equipment electrical connector (P202),
an outoftheway position when the brake is installed on the aft fuselage wiring harness
not in use. near the main transmission, is replaced with a
The rotor brake installation includes: new plug which mates with the receptacle on
the new tachometer generator.
(1). A master cylinder with an actuating
handle mechanism (master cylinder 3. Rotor Brake Troubleshooting Procedure
and linkage assembly). (Ref. Table 201)
(2). A caliper assembly with dual opposing 4. Master Cylinder Servicing
pistons to which friction pads (brake
pucks) are attached. (Ref. Figure 401)
(3). A brake disc installed on the tail rotor Consumable Materials

drive shaft coupling at the aft end of (Ref. Section 910000)
the main transmission. Item Nomenclature
(4). A hydraulic pressure relief valve. CM123 Hydraulic fluid
(5). A tachometer generator.

Rotor brake installation servicing includes
(6). Six stainless steel hydraulic tubing adding hydraulic fluid (CM123) to the master
assemblies and associated fittings. cylinder reservoir, and bleeding air from the
system.
(7). Attaching and mounting hardware.
(1). Remove interior trim to gain access to
(8). A trim panel assembly and installation. master cylinder.
2. Rotor Brake Operation (2). Disconnect tube assembly from forward

nipple and move end of tube assembly
When manual force is applied to the brake carefully aside to permit removal of
handle (master cylinder piston), hydraulic master cylinder cap.
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MAINTENANCE MANUAL
(3). Remove attaching screws, cap with NOTE: Hose material should be resistant to de-
assembled hydraulic parts, and gasket terioration from exposure to hydraulic fluid.
from master cylinder. Replace gasket. A glass container should be used to catch
bleed screw outflow so that bubbles of escap-
(4). Fill master cylinder reservoir with ing air are clearly visible. The following fill-
clean hydraulic fluid (CM123) within ing and bleeding procedure is best per-
1/8 to 1/4 inch (3.1756.35 mm) of the formed by two persons, one to operate the
top. Install cap with assembled hydrau- brake handle, and one to open and close the
lic parts, new gasket, and attaching bleed screws.
screws. Do not tighten screws if (3). Connect a length of 1/4 inch (6.35 mm)
hydraulic system is to be bled. ID hose on reducer and insert free end
of hose in a container to catch any
(5). If hydraulic system has been opened, hydraulic fluid that may be bypassed by
e.g. as for replacement of components, the relief valve. Connect a second
perform procedural steps to bleed the length of 1/4 inch (6.35 mm) ID hose on
hydraulic system. one bleed screw on caliper assembly
and submerge free end of hose in clean
hydraulic fluid (CM123) in a glass
NOTE: It is not necessary to bleed the system if container.
only a small amount of fluid is required to
fill the reservoir, and if the system has not (4). Remove attaching screws and master
been opened. cylinder cap. Fill reservoir with clean
hydraulic fluid (CM123) within 1/8
1/4 inch (3.1756.35 mm) of top of
(6). Tighten attaching screws to secure cap chamber. Replace cap, do not tighten
on master cylinder. Connect tube attaching screws.
assembly to nipple.
NOTE: Verify that master cylinder reservoir is
(7). Reinstall components removed for kept full of fluid throughout the bleeding
access to the master cylinder assembly. process.
(5). Open one bleed screw and operate
brake handle slowly through a full
5. Rotor Brake Hydraulic System Bleeding down stroke to force hydraulic fluid out
of master cylinder reservoir and into all
other parts of the system. Close bleed
Consumable Materials screw and return handle to "up"
(Ref. Section 910000) position. Remove cap, refill master
Item Nomenclature cylinder reservoir, and replace cap.
CM123 Hydraulic fluid (6). Repeat step (5). several times to ensure
that entire hydraulic system is filled
with fluid, and that no air remains in
The rotor brake hydraulic system must be bled system.
to remove entrapped air whenever the system
has been opened for any reason. NOTE: The presence of bubbles in the bleed
screw outlet flow indicates air is being
forced out of the system and absence of
(1). Remove interior trim for access to the bubbles indicates all air has been bled from
master cylinder assembly and bleed the system.
screws on caliper assembly (if applica-
ble). (7). Remove bleeder hose from first bleed
screw and connect it on second bleed
screw.
(2). Disconnect tube assembly from reducer
in relief valve and nipple in master (8). Repeat steps (5). and (6). until bleed
cylinder cap. screw outlet flow is clear of bubbles.
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MAINTENANCE MANUAL
(9). Remove fluid catch containers and 7. Master Cylinder Assembly Overhaul
hoses. Ensure both bleed screws are
tightly closed. Raise brake handle to (1). Remove defective master cylinder
stowed position and engage in handle assembly.
retainer assembly. Verify that caliper
pistons (and attached brake pucks) are (2). Disassemble unit and replace defective
retracted when handle is raised. parts with components of overhaul kit
(Vendor PN 128310), using manufac-
(10). Make final check of fluid level in
turers instructions supplied with kit.
master cylinder reservoir and replen-
ish, if necessary. Secure gasket and cap
with attaching screws. (3). Install overhauled master cylinder
assembly.
(11). Connect tube assembly to nipple in cap
and to reducer in relief valve and 8. Caliper Assembly Overhaul
tighten tube nuts.
(1). Remove defective caliper assembly.
6. Rotor Brake Component Repair
The master cylinder assembly or caliper (2). Disassemble unit and replace defective
assembly may be overhauled as necessary. parts with components of overhaul kit
Overhaul kits are available from MD Helicop- (Vendor PN 1211780), using manufac-
ters Inc. or an approved MD Helicopter service turers instructions supplied with kit.
center. Other parts must be replaced when
damaged or otherwise unserviceable. (3). Install overhauled caliper assembly.
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MAINTENANCE MANUAL
Table 201. Troubleshooting Rotor Brake Installation

Symptom Isolating Step Corrective Action
Brake actuating handle creeps Defective master cylinder assembly. Remove defective master cylinder
downward under sustained force, assembly and replace with new unit,
with hydraulic fluid leakage from or overhaul and reinstall old unit.
master cylinder assembly.
Brake actuating handle creeps Defective caliper assembly. Remove defective caliper assembly
downward under sustained force, and replace with new unit, or
with hydraulic fluid leakage from overhaul and reinstall old unit.
caliper assembly.
Spongy feel at brake actuating Air in hydraulic system. Bleed air from hydraulic system.
handle when force is applied.
Hydraulic fluid at low level in master Add fluid to master cylinder

cylinder reservoir. assembly and bleed air from
hydraulic system.
Rotor brake system fails to slow Any of above components or system Follow applicable corrective action
rotor effectively. faults. procedures.
Brake pucks worn excessively. Remove defective caliper assembly,

replace defective pucks and reinstall
repaired unit.
Brake pucks create noises, such Glazed or worn brake pucks. Remove defective caliper assembly,
as squeals or squeaks, when replace defective pucks and reinstall
brakes are applied. repaired unit.
Brake disc creates noises, such Scored or damaged brake disc. Remove defective brake disc and
as squeals or squeaks, when replace with new disc.
brakes are applied.
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MAINTENANCE MANUAL
ROTOR BRAKE
When working with hydrau- nience panel cover assembly from
WARNING lic systems, special care convenience panel assembly.
must be taken to prevent entrance of
dust, moisture or other foreign materi- (4). Disconnect electrical wiring and
al. System contamination can cause communications cables from compo-
malfunctions which could cause injury nents on back of convenience panel
to personnel or equipment damage. assembly. If cabin heating option is
installed on aircraft, disconnect heated
1. Rotor Brake Component Access air duct from panelmounted diffuser.
Remove attaching screws and conve-
The following items must be removed to gain nience panel assembly from aft side of
access for removal of rotor brake components. canted bulkhead 78.50 structure.
Removal should be limited to damaged or
defective parts for repair, overhaul or replace- (5). Remove transmission cover panel
ment, or to remove certain items for access to assembly from fuselage structure.
other components. (6). Cover exposed trim panels to prevent
damage and soiling.
The master cylinder assembly, linkage
assembly and hydraulic relief valve are (7). Remove main transmission from
installed on or attached to the helicopter aircraft (Ref. Sec. 632000/25).
structure. Removal of these components
require access from the crew compartment. (8). Remove tail rotor (Ref. Sec. 642000),
Hydraulic tube assembly is not attached to the tail rotor transmission (Ref. Sec.
helicopter structure. Access from the passen- 632510) and tail rotor drive shaft
ger/cargo compartment is required for removal (Ref. Sec. 631510).
of hydraulic tube assembly.
2. Master Cylinder Assembly Replacement
The caliper assembly and related hydraulic
items, caliper mounting bracket, tachometer (Ref. Figure 401 and Figure 402)
generator, brake disc and tail rotor drive A. Master Cylinder Assembly Removal
coupling are installed on the main transmis-
sion. Removal of these components require The master cylinder assembly is bolted to the
that certain access provisions be made and bracket of the master cylinder linkage assem-
that the main transmission, and attached rotor bly and is connected hydraulically to the
brake components, be removed from the caliper assembly. Remove master cylinder
aircraft. assembly as follows:
NOTE: Component removal can be accom- (1). Remove trim panels to gain access to
plished with the doors in place. However, op- master cylinder.
erations are facilitated with the doors re-
moved. (2). Disconnect tube assembly from nipple,
and tube assembly from elbow, taking
(1). Remove both crew compartment and special care to catch any hydraulic fluid
cargo/passenger compartment doors. that drains or drips from tube assem-
blies or fittings when the system is
(2). Remove crew compartment seats. opened.
(3). Remove map case assembly from NOTE: If old master cylinder assembly is to be
forward side of canted bulkhead 78.50 reinstalled, removal of tube assembly, nip-
structure. Remove both (LH and RH) ples, and elbow may not be necessary unless
upper forward panel assemblies from the tube assembly or fittings are damaged
bulkhead structure. Remove conve- or defective.
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MAINTENANCE MANUAL
MAST SUPPORT PAN
WINDOW SUPPORT
CHANNEL ASSEMBLY
TEE
PRESSURE RELIEF
VALVE
VENT
MASTER CYLINDER
ACTUATING LINKAGE
LEFTHAND INSTALLATION SHOWN; RIGHTHAND OPPOSITE G632003A
Figure 401. AirframeMounted Rotor Brake Components
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Revision 20 632200
MAINTENANCE MANUAL
(3). Remove tube assembly from nipple. NOTE: Mounting holes in bracket are elon-
Remove nipples from cap, and elbow gated to enable lateral position adjustment
from master cylinder. of master cylinder assembly.
(4). Remove nuts, washers, bolts, stop, and (6). With actuating handle in stowed
master cylinder assembly from bracket. position, adjust position of master
Drain residual hydraulic fluid from cylinder assembly so that clearance
master cylinder assembly. (measured with a thickness gage)
between actuating lever (Ref.
(5). Install protective caps or plugs on open Figure 905) and master cylinder piston
ends of disconnected tube assemblies, is 0.0200.040 inch (0.5081.016 mm).
and open ports or fittings in master
cylinder assembly to prevent entry of (7). Install tube assembly on aft nipple.
contaminants. Connect tube assembly to forward
B. Master Cylinder Assembly Installation nipple and connect tube assembly to
elbow.
Consumable Materials (8). Fill and bleed the hydraulic system.

Item Nomenclature (9). Reinstall components removed for
CM434 Thread sealant access to the master cylinder assembly.
3. Master Cylinder Linkage Assembly

NOTE: Steps (1). thru (3). below apply only to Replacement
installation of a new master cylinder assem-
bly. (Ref. Figure 402)
(1). Remove attaching screws and vendor A. Master Cylinder Linkage Assembly
supplied cap from master cylinder. Removal
Vendor supplied cap is not used.
The bracket assembly of the master cylinder
(2). Rework vendorsupplied gasket (Ref. linkage assembly is permanently installed on
Figure 906). the canted bulkhead Sta. 78.50 vertical
member by four Jobolt blind fasteners. Once
(3). Replace reworked gasket and new cap
installed, the Jobolts cannot be removed
on master cylinder and secure with
except by destructive procedures. The master
attaching screws installed finger tight.
cylinder and linkage assembly may be disas-
NOTE: Cap must be installed correctly with re- sembled, leaving the bracket assembly
spect to taper of threaded holes. attached to the structure. Disassembly should
be limited to that necessary for removal of
(4). If new master cylinder assembly is damaged or defective parts.
being installed, or if hydraulic fittings
have been removed from a usable unit, (1). Remove master cylinder.
coat all but first two tapered pipe
threads of nipples and elbow with When components are as-
thread sealant (CM434). Install nipples WARNING sembled, spring force is con-
in cap and elbow in master cylinder. stantly exerted to inhibit inadvertent
brake application. Care must be exer-
(5). Place one washer and stop on bolts and cised as the spring is disengaged to
insert bolts through master cylinder. prevent injury to personnel or equip-
Place two washers on each bolt as ment damage.
spacers. Position assembled parts on
bracket (Ref. Figure 402) and install (2). Manually restrain movement of lever
one washer on each bolt. Install nuts and attached parts. Carefully disengage
finger tight to hold master cylinder end of spring from under head of clevis
assembly and stop in position. pin. Release spring force carefully.
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MAINTENANCE MANUAL
BRACKET
ASSY STOP
NUT
WASHER BOLT
ACTUATING LEVER
GRIP SPACER
NUT
WASHER
PIN COTTER
PIN
HANDLE ROLL PIN
SPRING
COTTER PIN NUT
WASHER
FITTING
WASHER
CLEVIS PIN G632006
Figure 402. Master Cylinder Linkage Assembly
(3). Remove cotter pin, nut, washer, spring, B. Master Cylinder Linkage Assembly
and lever with assembled handle parts Installation
from pin.
Installation of the master cylinder linkage
assembly will be limited to reassembly of
(4). Remove cotter pin, washers, and clevis components to the bracket assembly.
pin, and separate assembled handle
parts from lever. Remove nut, spacer, When the unit is assembled,
and bolt from lever. WARNING the spring is under restraint
and, if accidentally or inadvertently re-
(5). Drive two spring pins out of fitting and leased, could cause injury to personnel
handle and separate parts. Remove grip or equipment damage.
from handle.
(1). Reassembly procedures are essentially
the reverse of disassembly procedures,
(6). Remove nut and washer from pin, and with special care being given to steps
remove pin from bracket assembly. involving spring.
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MAINTENANCE MANUAL
(2). If cotter pins or spring pins have been NOTE: If old caliper assembly is to be rein-
removed, use new parts for reassembly. stalled, it is not necessary to remove hy-
draulic fittings except for replacement of de-
4. Caliper Assembly, Brake Disc, and Drive fective or damaged parts.
Coupling Replacement (369D25100
Transmission) (4). Remove coupling bolt that is used to
secure drive coupling on transmission
(Ref. Figure 403) output shaft so that disc/coupling unit
is free to slide on shaft splines.
A. Caliper Assembly, Brake Disc, and Drive
Coupling Removal (369D25100 (5). Note and record, for reassembly
Transmission) reference, placement of 18 washers
used as spacers between caliper
The caliper assembly is bolted to a mounting assembly and mounting bracket, or
bracket which is installed on the main under heads of attaching bolts.
transmission tail rotor cover. The brake disc is
bolted on the drive coupling which is installed
on the transmission output shaft. For clarity, The caliper assembly consists of
CAUTION two identical halves held togeth-
the brake disc and drive coupling are consid-
ered as a single item (disc/coupling unit). er by the attaching bolts. Care should be
used to avoid dropping parts when bolts are
Although the caliper assembly and the removed.
disc/coupling unit are not mechanically
connected, they are installed on the transmis- (6). Hold caliper assembly and unscrew
sion with the outer portion of the disc posi- attaching bolts out of mounting brack-
tioned between the two halves of the caliper et. Slide disc/coupling unit away from
assembly (Ref. Figure 404). This arrangement transmission and remove caliper
makes it necessary to remove both units assembly and attaching hardware.
(partially, at least) at the same time. Removal
operations require that the main transmission (7). If caliper assembly is to be reused and
be removed from the aircraft with the rotor some time will elapse before reassemb-
brake components installed. Proceed as ly, remove disc/coupling unit, position
follows: caliper assembly (and assembled parts)
on mounting bracket and screw bolts
(1). Remove main transmission and into bracket to hold parts until time for
attached rotor brake components from reassembly.
aircraft (Ref. Sec. 632000/25).
(2). Disconnect tube assembly from caliper (8). If disc/coupling unit is to be reinstalled,
mounted tees. Remove tube assembly and some time will elapse before
and interconnect tee as a unit. reassembly, slide unit back on trans-
mission shaft and install coupling bolt
NOTE: finger tight to hold parts until time for
reassembly.
D It is not necessary to disconnect tube as-
semblies from tee except for replacement Axial position of the drive
of defective and damaged parts. WARNING coupling is critical as it con-
D New bleed screws are included with the trols the mechanical interface between
new caliper assembly. the coupling and the tail rotor drive
shaft. Outoftolerance axial coupling
(3). If caliper assembly is to be replaced by loads can contribute to coupling fail-
a new unit, remove two bleed screws ure which could result in injury to per-
from adapters, remove adapters from sonnel and equipment damage. Refer
tees, and remove tees from caliper to Sec. 631000 for coupling reinstalla-
assembly. tion.
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MAINTENANCE MANUAL
BLEEDSCREWS PISTON CALIPER

SPECIAL NUT ASSEMBLY
GASKET
SPACER
WASHER
ROTOR
TACHOMETER
GENERATOR
SHIM WASHERS
MOUNTING BRACKET
FAILSAFE COUPLING BOLT
TAIL ROTOR DRIVE

SHAFT COUPLING
COUPLING
SHIMS
EARLY CONFIGURATION
BRAKE DISC
COUPLING
BOLT
TRANSMISSION
COUPLING
COUPLING
SHIM
G632005A
Figure 403. TransmissionMounted Rotor Brake Components
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MAINTENANCE MANUAL
(9). If either disc or coupling is to be Molykote metal protector

replaced by a new part, slide disc/coup- WARNING contains perchloroethylene.
ling unit off shaft, leaving shim wash- It should be used in a wellventilated
ers in place. Remove nuts, washers, and area, and the precautions normally fol-
bolts and separate disc and coupling. If lowed when working with the chlori-
coupling is being replaced, measure nated solvent should be implemented.
(and record for reassembly reference) Solvents used to dilute this material, as
overall length of old coupling at three well as metalcleaning or alkali cleans-
separate peripheral locations. Calculate ers, should only be used with adequate
and record the average value. ventilation. Follow handling precau-
tions on the solvents container label.
B. Caliper Assembly, Brake Disc and Drive NOTE: Couplings should be treated with moly-
Coupling Installation (369D25100 kote metal protector (CM202) after each
Transmission) washing with any solvent or detergent.
(4). Spray molykote metal protector

Consumable Materials (CM202) on the interior and exterior
(Ref. Section 910000) surfaces of Bendix coupling diaphragm
Item Nomenclature packs. Spray or dip flange in molykote
metal protector. Eliminate excess liquid
CM112 Antiseize compound high temperature by gently blowing with compressed air
CM117 Grease (dilute to 10% perchloroethylene). Cure
CM202 Metal protector, aerosol
for 8 hours at room temperature, or 15
minutes at 150F (65C).
CM434 Thread sealant
CM702 Lockwire CRES (5). Coat, completely but sparingly, splines
of transmission output shaft with
grease (CM117) and threads of coupling
bolt with antiseize compound
(1). Position brake disc on drive coupling (CM112), or equivalent. Start disc/coup-
with raised center side of disc seated ling unit on shaft.
firmly on shoulder of coupling, and with
bolt holes aligned. Insert four bolts To ensure optimum brake opera-
through disc and coupling flange, CAUTION tion and minimize equipment
install washers and nuts on bolts, and damage, calipertodisc clearances on both
torque nuts (in an alternating se- sides of disc should be equal, or as nearly
quence) to 100 140 inchpounds equal as possible. Clearance adjustment is
(11.30 15.82 Nm). accomplished by varying number of shim
washers, 0.032 inch (0.8128 mm) thick,
placed between the caliper assembly and its
The main transmission must mounting bracket. Nine washers are pro-
WARNING be installed in the aircraft
vided for each attaching bolt; those not used
with special care to avoid damage to as shims should be placed under bolt heads.
rotor brake components. Installation Washer distribution should be the same for
damage could lead to system failure both bolts.
which could result in injury to person-
nel and equipment damage. (6). Hold assembled parts with caliper
assembly over edge of disc, slide
(2). Install transmission in aircraft (Ref. disc/coupling unit on shaft, and move
Sec. 632000/25). caliper assembly against mounting
bracket at the same time. Screw bolts
into bracket to hold caliper assembly
(3). Determine correct shimming for firmly in position. Screw coupling bolt
coupling (Ref. Sec. 631000). into shaft to secure disc/coupling unit.
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MAINTENANCE MANUAL
DISC
CALIPER
CALIPER
MOUNTING CALIPER
SHIM WASHERS
BRACKET ASSEMBLY
DRIVE SHAFT COUPLING

(KAMATIC)
NOTE
BRAKE DISC/BRAKE
PUCK CLEARANCES
TAIL ROTOR
DRIVE SHAFT
DRIVE SHAFT COUPLING
(BENDIX)
COUPLING
SHIMS
MAIN TRANSMISSION
NOTE:
CLEARANCE TO BE EQUAL TO WITHIN 0.032 IN. (0.8128 MM). G632010B
Figure 404. Caliper Assembly and Brake Disc Interface (369D25100 Transmission)
LOCKWIRE MAIN TRANSMISSION

BOLT BOLT
LOCKWIRE
SPECIAL NUT
CALIPER MOUNTING
BRACKET
DRIVE COUPLING G632011
Figure 405. Lockwire Installation (369D25100 Transmission)
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Revision 20 632200
MAINTENANCE MANUAL
(7). Measure brake caliper housingtodisc NOTE: It is not necessary to remove washers
clearances on both sides of disc with a used as spacers except for replacement.
thickness gage. If clearances are equal Nuts may be replaced on studs until time for
within 0.032 inch (0.8128 mm), torque reassembly to prevent loss of parts.
attaching bolts to 160 190 inch
pounds (18.0821.47 Nm) and secure B. Caliper Mounting Bracket Installation
with corrosionresistant lockwire (369D25100 Transmission)
(CM702) (Ref. Figure 405). Torque The following procedures assume that the
coupling bolt per Section 631000. transmission has been removed from the
aircraft for removal of the mounting bracket.
NOTE: Clearance differences greater than
0.032 inch (0.8128 mm) can be reduced by
rearranging washers on caliper attaching Consumable Materials
bolts. (Ref. Section 910000)
Item Nomenclature
(8). To adjust clearances, hold caliper CM702 Lockwire CRES
assembly and unscrew bolts from
mounting bracket. Transpose washers
on bolts as required. Reassemble parts, (1). Place three washers on each of the four
and recheck clearances. mounting studs (1, 2, 10, and 11 oclock
positions) as spacers. Position mounting
(9). If new caliper assembly was installed or bracket on studs, install washers and
if hydraulic fittings were removed from nuts, and torque nuts to 50 75
old unit, coat all but first two threads of inchpounds (5.65 8.47 Nm).
two bleed screws, tees, and plugs with
thread sealant (CM434) or equivalent. (2). Secure installation with lockwire
Install plugs and tees in caliper (CM702) (Ref. Figure 405).
assembly, screw adapters on tees, and (3). Reinstall transmission as required (Ref.
install bleed screws in adapters. Sec. 632000/25).
(10). Connect tube assemblies and tee unit to 6. Caliper Assembly, Brake Disc, and Drive
tees. Coupling Replacement (369F5100
Transmission)
5. Caliper Mounting Bracket Replacement
(369D25100 Transmission) (Ref. Figure 406)
A. Caliper Assembly, Brake Disc, and Drive
(Ref. Figure 403)
Coupling Removal (369F5100
A. Caliper Mounting Bracket Removal Transmission)
(369D25100 Transmission) The caliper assembly is bolted to the main
transmission antitorque cover. The brake disc
The caliper mounting bracket is attached to
is bolted on the drive coupling which is
the main transmission tail rotor cover by
installed on the transmission output shaft. For
special nuts installed on four of the studs used
clarity, the brake disc and drive coupling are
for installation of the cover. The caliper
considered as a single item (disc/coupling
assembly is bolted to the mounting bracket.
unit). Although the caliper assembly and the
Bracket removal requires that the main
disc/coupling unit are not mechanically
transmission be removed from the aircraft
connected, they are installed on the transmis-
with the rotor brake components installed.
sion with the outer portion of the disc posi-
(1). Remove main transmission (and tioned between the two halves of the caliper
attached rotor brake components) from assembly. This arrangement makes it neces-
aircraft (Ref. Sec. 632000/25). sary to remove both units (partially, at least)
at the same time. Removal operations require
(2). Remove attaching nuts and washers, that the main transmission be removed from
and remove mounting bracket from the aircraft with the rotor brake components
studs. installed.
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632200 Revision 20
MAINTENANCE MANUAL
(1). Remove main transmission (and (8). If disc/coupling unit is to be reinstalled,

attached rotor brake components) from and some time will elapse before
aircraft (Ref. Sec. 6325). reassembly, slide unit back on trans-
mission shaft and install coupling bolt
(2). Disconnect tube assembly from caliper finger tight to hold parts until time for
mounted tees. Remove tube assembly reassembly.
and interconnect tee as a unit.
Axial position of the drive
NOTE: It is not necessary to disconnect tube WARNING coupling is critical as it con-
assemblies from tee except for replacement trols the mechanical interface between
of defective and damaged parts. the coupling and the tail rotor drive
shaft. Outoftolerance axial coupling
(3). If caliper assembly is to be replaced by loads can contribute to coupling fail-
a new unit, remove two bleed screws ure which could result in injury to per-
from adapters, remove adapters from sonnel and equipment damage. Refer
tees, and remove tees from caliper to Sec. 6315 for coupling reinstalla-
assembly. tion.
NOTE: If old caliper assembly is to be rein- (9). If either disc or coupling is to be

stalled, it is not necessary to remove hy- replaced by a new part, proceed as
draulic fittings except for replacement of de- follows:
fective or damaged parts.
(a). Slide disc/coupling unit off shaft,
(4). Remove coupling bolt that is used to leaving shim washers in place.
secure drive coupling on transmission
output shaft so that disc/coupling unit (b). Remove nuts, washers, and bolts and
is free to slide on shaft splines. separate disc and coupling.
(5). Note and record, for reassembly (c). If coupling is being replaced, mea-
reference, placement of 18 washers sure (and record for reassembly
used as spacers between caliper reference) overall length of old
assembly and mounting bracket, or coupling at three separate peripheral
under heads of attaching bolts. locations.
The caliper assembly consists of
CAUTION two identical halves held togeth-
(d). Calculate and record the average
value.
er by the attaching bolts. Care should be
used to avoid dropping parts when bolts are B. Caliper Assembly, Brake Disc and Drive
removed. Coupling Installation (369F5100
Transmission)
(6). Hold caliper assembly and unscrew
attaching bolts. Slide disc/coupling unit
The following procedure is for installation of
away from transmission and remove
the rotor brake caliper assembly. The caliper
caliper assembly and attaching hard-
assembly should be installed on the transmis-
ware.
sion before the transmission is installed in the
helicopter.
(7). If caliper assembly is to be reused and
some time will elapse before reassemb-
ly, remove disc/coupling unit, position Consumable Materials
caliper assembly (and assembled parts) (Ref. Section 910000)
on transmission and insert bolts to hold Item Nomenclature
parts until time for reassembly.
CM434 Thread sealant
NOTE: New bleed screws are included with the CM702 Lockwire CRES
new caliper assembly.
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MAINTENANCE MANUAL
AN960616LL
CALIPER MOUNTING BOSS
WASHER
ON TRANSMISSION
(NOTE 1)
HS4620C1929 AN960616LL
BUSHING WASHER
(NOTE 1)
NAS6606H52
BOLT
(NOTE 3)
CALIPER
ASSEMBLY
DISC DISC
CALIPER CALIPER
NOTES:
1. CLEARANCE TO BE ADJUSTED BY VARYING WASHERS FROM EITHER SIDE
OF CALIPER ASSEMBLY.
2. CLEARANCE TO BE EQUAL WITHIN 0.032 IN. (0.8128 MM). NOTE 2
3. TORQUE TO 160 190 INCH POUNDS (18.08 21.47 NM) AND SAFETY WITH
LOCKWIRE (CM702). CSP102010A
Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission)
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MAINTENANCE MANUAL
NOTE: (5). Install plugs and tees in caliper

assembly, screw adapters on tees and
D AN960616LL washers are to be used for
install bleed screws in adapters.
adjusting calipertodisc clearance.
D Nine washers are used on each attaching (6). Connect tube assemblies and tee units
bolt; those not used as shims should be to tees.
placed under bolt heads. Washer distribu- 7. Hydraulic Relief Valve Replacement
tion should be the same for both bolts.
(Ref. Figure 401)
(1). Insert two bolts with equal number of
washers through the caliper (washers A. Hydraulic Relief Valve Removal
can be on either side of caliper as The hydraulic relief valve is attached by
needed) and install two bushings. means of a clamp to the canted bulkhead 78.50
vertical member, and is connected hydraulical-
NOTE: On the 369F5100 transmission, the ly between the master cylinder assembly and
brake caliper bolts directly to the transmis- the caliper assembly. Remove the relief valve
sion. as follows:
(2). Mount the caliper assembly over disc (1). Remove crew compartment hardware
and thread bolts into transmission. and fittings for access to hydraulic
relief valve assembly.
To ensure optimum brake opera-
CAUTION tion and minimize equipment
(2). Disconnect tube assembly from reducer
installed in relief valve. Disconnect
damage, calipertodisc clearances on both tube assembly from relief valve, taking
sides of disc should be equal, or as nearly special care to catch any hydraulic fluid
equal as possible. Clearance adjustment is that drains or drips from tube assem-
accomplished by varying number of 0.032 blies, reducer, or relief valve when the
inch (0.8128 mm) thick shim washers placed system is opened. Remove reducer and
between the caliper assembly and transmis- Oring packing from relief valve.
sion. Discard Oring packing.
(3). Measure brake caliper housingtodisc NOTE: Because of limited access, it may be
clearances on both sides of disc with a more convenient to disconnect tube assem-
feeler gage. If clearances are equal bly from tee before removing tube assembly
within 0.032 inch (0.8128 mm), torque from relief valve. If so, remove tube assem-
attaching bolts to 160 190 inch bly from tee; remove relief valve and tube
pounds (18.08 21.47 Nm) and secure assembly from helicopter; and remove tube
with lockwire (CM702). from relief valve. Reinstall tube assembly on
tee finger tight for storage until required for
NOTE: Clearance differences greater than replacement of relief valve.
0.032 inch (0.8128 mm) can be reduced by
rearranging washers on caliper attach (3). Remove screw, washer, and clamp, and
bolts. remove relief valve from canted bulk-
head 78.50 structure.
(4). To adjust clearances, hold caliper (4). Install protective caps or plugs on open
assembly and unscrew bolts from relief valve ports and open ends of
mounting bracket. Transpose washers disconnected tube assembly to prevent
on bolts as required. Reassemble parts entrance of contaminants.
and recheck clearances.
B. Hydraulic Relief Valve Installation
NOTE: If new caliper assembly was installed or Installation procedures are essentially the
if hydraulic fittings were removed from old reverse of removal procedures, with these
unit, coat all but first two threads of two special considerations:
bleed screws, tees and plugs with thread
sealant (CM434) or equivalent. (1). Install new Oring packing on reducer.
Page 412
Revision 20 632200
MAINTENANCE MANUAL
(2). After relief valve is installed and B. Hydraulic Tube Assembly Installation
connected into the hydraulic system, fill
and bleed the system. Tube assembly installation is essentially the
reverse of removal procedures, with these
(3). Reinstall components removed for specific considerations.
access to the hydraulic relief valve.
8. Hydraulic Tube Assembly Replacement (Ref. Section 910000)
Item Nomenclature
(Ref. Figure 904) CM418 Cement, epoxy
A. Hydraulic Tube Assembly Removal

(1). Make a straight radial cut into center
The hydraulic tube assembly is attached to the hole of new grommet and install
main rotor mast pan and to the window grommet on tube assembly. Position
channel by four clamps. It is connected parts and bond grommet into slot in air
between tees. The assembly removal requires baffle with epoxy cement (CM418).
access from the cargo/passenger compartment. (2). Fill and bleed the hydraulic system.
(1). Remove attaching screws and both (LH (3). Reinstall components removed for
and RH) upper forward trim panel access to the hydraulic tube assembly.
assemblies. Remove convenience panel
cover assembly. Remove attaching 9. Rotor Brake Forward Cover Assembly
screws and transmission cover panel Installation
assembly.
(Ref. Figure 908)
(2). Disconnect tube assembly from tees, (1). Position cover assembly on map case
taking special care to catch any hydrau- assembly with rotor brake handle and
lic fluid that drains or drips from tube handle retaining clip through cover
assembly or tees when system is openings. Aft edge of cover must
opened. overlap forward edge of convenience
panel cover assembly. Install attaching
(3). Remove (and discard) grommet from screw through cover assembly and map
tube assembly and air baffle. case panel into isolation mount on
canted bulkhead 78.50 structure.
(4). Remove nuts, washers, screws, clamps,
and tube assembly. (2). On the 369D, secure cover assembly
and doublers to angle assembly with
(5). If some time is to elapse before reas- attaching screw. On the 369E/FF,
sembly, install protective caps on open secure cover assembly to convenience
ends of tees to prevent entrance of panel, using shims and attaching
contaminants. screws.

632200 Revision 20
MAINTENANCE MANUAL
ROTOR BRAKE
INSPECTION/CHECK
When working with hydrau- (5). Verify that clip (Ref. Figure 901) on
WARNING lic systems, special care handle retainer assembly holds brake
must be taken to prevent entrance of handle securely in the stowed (raised)
dust, moisture. and other foreign mate- position.
rial. System contamination can cause
malfunctions that could result in inju- (6). Actuate brake handle to check that
ry to personnel and equipment dam- components of master cylinder linkage
age. assembly (Ref. Figure 402) operate
freely without binding or excessive play
1. Rotor Brake Assembly Inspection at pivot points. Verify that spring force
holds lever in BRAKE OFF position.
Consumable Materials (7). Visually inspect friction surfaces of

(Ref. Section 910000) brake disc (Ref. Figure 403) for exces-
Item Nomenclature sive wear, galling, scoring, cracking,
CM123 Hydraulic fluid distortion, or other evidence of damage.
(8). Rotate the drive system and check that

(1). Visually inspect rotor brake compo- caliper brake pucks are not dragging on
nents for general condition, security of the disc.
installation, and evidence of hydraulic (9). Apply sufficient force on brake handle
fluid leakage. to actuate master cylinder assembly to
pressurize hydraulic system.
NOTE: Excessively low fluid level indicates a
system fault that must be isolated and cor- NOTE: System pressurization (brake actua-
rected. tion) is indicated by the feel of firm resis-
tance to handle movement. A cushioned
(2). Disconnect tube assembly (Ref. (spongy) feel indicates that the system con-
Figure 902) from nipple installed in tains air which must be removed (bled off)
master cylinder cap. Move end of tube before proceeding with the inspection.
assembly carefully aside, remove
attaching screws and cap with gasket, (10). Maintain force on brake handle and
and check that hydraulic fluid level is verify that pistons in caliper assembly
1/8 1/4 inch (3.1756.35 mm) from top operate to force brake pucks against
of reservoir. If level is low, add hydrau- friction surfaces of brake disc. Visually
lic fluid (CM123). Take special care to inspect brake pucks for extent of wear
avoid getting contaminants into the and evidence of damage.
hydraulic system.
Do not apply a side load to brake
(3). Visually inspect gasket for tears, cuts, CAUTION handle as damage to support
or other damage; replace gasket, if bracketry may result.
defective. Visually inspect sealing
surfaces of cap and master cylinder NOTE: Pucks must be extended to the BRAKE
body for nicks, cracks, scratches, or ON position to permit adequate inspection.
other defects; repair minor damage or If parting line between piston face and puck
replace defective parts. is visible, puck is worn excessively and must
be replaced.
(4). Replace cap and gasket on master
cylinder and secure with attaching (11). Monitor feel of resistance and increase
screws. Connect tube assembly to force applied to brake handle until
nipple and tighten tube nut securely. hydraulic relief valve opens.
Page 601
632200 Revision 20
MAINTENANCE MANUAL
NOTE: When working properly, the hydraulic (15). Raise brake handle to stowed position
relief valve opens and routes pressurized and engage it in clip on handle retainer
hydraulic fluid back to the master cylinder assembly.
reservoir when system pressure reaches 500
psig (3447 kPa). Valve opening can be de- 2. Rotor Brake Operational Check
tected by a momentary decrease of resis-
tance to handle movement. If movement is After rotor brake hydraulic system has been
solidly resisted, regardless of force applied, filled with fluid, an operational checkout of the
the relief valve is defective and must be re- rotor brake installation must be performed.
placed. (1). Start engine, run up rotor to operating
(12). Maintain steady force (just short of that speed, and then make a normal shut-
required to initiate relief valve opening) down (refer to applicable Pilots Flight
on brake handle and observe handle Manual).
movement. Check that actuating lever Incorrect application of the ro-
spacer and master cylinder stop do not CAUTION tor brake can result in sudden
contact. stopping and kickback of the main rotor, an
Check for installation of master action which can cause damage to the rotor
CAUTION cylinder stop to prevent over blades and strap packs in the rotor hub. Col-
travel of piston in master cylinder. If stop is lective pitch must never be applied to slow
not installed, damage to master cylinder rotor rotation as this can cause damage to
components may occur. the rotor blades and strap packs. Applica-
tion of a side load to brake handle may dam-
NOTE: Continued handle movement indicates age support bracketry.
the presence of an internal leak condition
which must be located and corrected. (2). When rotor slows to approximately 205
or less rpm, disengage brake handle
(13). Release force on brake handle and from retaining clip and pull handle
verify that caliper pistons (and attached down to apply braking force. Make
brake pucks) are retracted. certain that collective pitch stick is in
full down position, and that cyclic
NOTE: Failure of pistons to retract indicates control stick is in neutral position.
that caliper assembly is defective and must
be overhauled or replaced. (3). Release brake pressure during last
revolution of rotor.
(14). Reinstall components that were
removed for access to the rotor brake (4). Raise brake handle to stowed position
system. and engage it in handle retaining clip.
Page 602
Revision 20 632200
MAINTENANCE MANUAL
ROTOR BRAKE
When working with hydrau- NOTE: A new design convenience panel cover
WARNING lic systems, special care assembly (Ref. Figure 908) must be in-
must be taken to prevent entrance of stalled to cover the aft portion of the brake
dust, moisture, or other foreign materi- master cylinder assembly.
al. Hydraulic system contamination
can cause malfunctions that could re- (4). Disconnect electrical wiring and
sult in injury to personnel or equip- communications cables from compo-
ment damage. nents on back of convenience panel
assembly. If cabin heating option is
1. Rotor Brake Initial Installation installed on aircraft, disconnect heated
air duct from panelmounted diffuser.
This section provides detailed instructions for Remove attaching screws and conve-
accomplishing initial installation of the rotor nience panel assembly from aft side of
brake components into the aircraft. In general, canted bulkhead 78.50 structure.
procedures are applicable to either left hand or
right hand command configurations. Where (5). Remove transmission cover panel
pertinent, differences are specified. assembly from fuselage structure.
(6). Cover exposed trim panels to prevent
Illustrations are included to provide data
damage and soiling.
pertinent to aircraft modifications required for
installation of the rotor brake components. All (7). Remove main transmission from
items and tools required to install the rotor aircraft (Ref. Sec. 632000/25).
brake are standard and should be procured
locally. Alternate items of comparable charac- (8). Remove tail rotor (Ref. Sec. 642000),
teristics and equal quality may be used. tail rotor transmission (Ref. Sec.
632510) and tail rotor drive shaft
A. Aircraft Preparation (Ref. Sec. 631510).
Preparation for installation of rotor brake C. Removing Components to be Replaced
components include removal of certain original
equipment items to gain access, or for replace- Certain rotor brake and related components
ment. Preparations also include permanent are mounted on the main transmission, and
installation of certain rotor brake components. are installed in the aircraft as a unit with the
transmission. Some of these transmission
B. Installation Access mounted components replace similar item
counterparts that were used in the original
NOTE: The main transmission must be reinstallation.
moved from the aircraft to permit installa-
tion of the transmissionmounted rotor (1). The tail rotor drive coupling installed
brake components. on the transmission output shaft must
be replaced by a new drive coupling on
(1). Remove both crew compartment and which the brake disc is mounted.
cargo/passenger compartment doors. Remove coupling and failsafe device (if
used) from transmission output shaft
(2). Remove crew compartment seats. (Ref. Sec. 631510). Leave laminated
shim washers on output shaft and
(3). Remove map case assembly from retain coupling bolt for reassembly use.
forward side of canted bulkhead 78.50
structure. Remove both (LH and RH) (2). The tachometer generator installed on
upper forward panel assemblies from the tail rotor cover assembly on main
bulkhead structure. Remove conve- transmission must be replaced by a new
nience panel cover assembly from unit that provides clearance for the
convenience panel assembly. rotor brake disc. Remove attaching nuts
Page 901
632200 Revision 20
MAINTENANCE MANUAL
and washers, tachometer generator and (4). Attach angle assembly to shoulder
gasket from tail rotor cover assembly. beam with blind rivets.
Retain nuts and washers for reas-
sembly use. Tachometer generator will E. Master Cylinder Linkage Assembly and
not be reinstalled. Discard gasket. Mount Bracket Installation
(3). The tail rotor cover assembly is in- (Ref. Figure 901) The master cylinder linkage
stalled on the main transmission assembly bracket must be installed on canted
housing with nuts and washers in- bulkhead 78.50 vertical member as a means of
stalled on twelve studs. Four of the attachment for the master cylinder assembly
studs, with special nuts and washers, and the other components of the master
will be used for installing the rotor cylinder linkage assembly.
brake caliper mounting bracket.
Remove four nuts and washers (at 1, 2,
10, and 11 oclock positions). These nuts Consumable Materials
and washers will not be used at (Ref. Section 910000)
reinstallation. Item Nomenclature
CM318 Primer
D. Angle Assembly Installation (500D)
(Ref. Figure 901) The angle assembly must be NOTE: Because of its method of attachment, it
installed on canted bulkhead 78.50 shoulder may be more convenient to install the link-
beam as a means of attachment for the age assembly bracket and then assemble
convenience panel cover assembly and the the other components on the bracket. Al-
rotor brake forward cover assembly. though the procedures given in steps (1).
thru (3). below consider installation of the
assembly, they are also applicable for instal-
Consumable Materials lation of the bracket. Steps (4). thru (7). be-
(Ref. Section 910000) low describe procedures for assembling com-
Item Nomenclature ponents to the bracket.
CM318 Primer
(1). Position master cylinder linkage
assembly on canted bulkhead 78.50
(1). Lay out and mark location for angle vertical member. Hold assembly (with
assembly on portion of forward bulk- bracket) firmly in position as a guide
head aft panel assembly that covers and use a No. 15 drill bit to line drill
canted bulkhead 78.50 shoulder beam. four holes in vertical member, taking
care to prevent point of drill bit from
(2). Insert piece of cardboard (or similar penetrating into vertical member more
material) under aft panel assembly to than 1/4 inch (6.35 mm).
protect shoulder beam and use a sharp
knife to make panel cut out to accom- (2). Line ream holes 0.1990.202 inch
modate angle assembly, taking special (5.05465.1308 mm) diameter. Remove
care not to cut outside marked area. linkage assembly, deburr holes in both
parts, and touch up raw metal surfaces
(3). Position angle assembly on shoulder with primer (CM318).
beam as a guide and drill two
0.1280.132 inch (3.25123.3528 mm) (3). Attach bracket to vertical member with
diameter holes through angle assembly Jobolt blind fasteners.
and one wall of shoulder beam, taking
care that point of drill bit does not (4). Secure pin (Ref. Figure 402) in bracket
penetrate into shoulder beam more with nut and washer.
than 1/4 inch (6.35 mm). Deburr holes
in both parts and touch up raw metal (5). Install grip on handle. Install new roll
surfaces with primer (CM318). pins through handle and fitting.
Page 902
Revision 20 632200
MAINTENANCE MANUAL
JOBOLT
RIGHTHAND
INSTALLATION
0.75 IN.
(19.05 MM)
0.50 IN.
(12.70 MM)
NOTE:
LEFTHAND INSTALLATION SHOWN, RIGHTHAND
OPPOSITE EXCEPT WHERE NOTED.
G6320121
Figure 901. Locating Permanently Installed Components (Sheet 1 of 2)
Page 903
632200 Revision 20
MAINTENANCE MANUAL
1.00 IN.
(2.54 CM) 0.50 IN.
0.063 IN.
(1.6002 MM) (12.70 MM)
(STOCK)
1.50 IN.
0.47 IN. (3.81 CM) 1.00 IN.
(11.938 MM) (2.54 CM)
0.31 IN.
0.75 IN. 2.00 IN. (7.87 MM)
(19.05 MM) (5.08 CM)
2.26 IN. 0.54 IN.

(5.7404 CM) (13.716 MM)
4.80 IN. 0.38 IN.

(12.192 CM) (9.652 MM)
1.80 IN. 0.25 IN.

(4.572 CM) (6.35 MM) (TYP)
0.70 IN.
(17.78 MM)
0.40 IN. 0.38 IN.

(10.16 MM) (9.652 MM) 3.07 IN. 0.50 IN.
(TYP) 0.38 IN. (7.7978 CM) (12.70 MM)
0.50 IN. (9.652 MM)
(12.7 MM) 2.38 IN.
4.57 IN. (6.0452 CM)
(11.6078 CM)
0.32 IN.
0.62 IN. (8.128 MM)
(15.748 MM)
0.50 IN.
(12.70 MM)
23.80 IN.
(60.452 CM)
HANDLE RETAINER ASSY

G6320122
Figure 901. Locating Permanently Installed Components (Sheet 2 of 2)
Page 904
Revision 20 632200
MAINTENANCE MANUAL
(6). Install bolt, spacer, and nut on lever. Remove retainer assembly and use a
Attach assembled handle parts to lever, 1/8 inch (3.175 mm) drill bit to drill out
with clevis pin, washers, and new cotter marked rivets.
pin.
(3). Lay out hole patterns on handle
When parts are assembled, retainer assembly to match drilled rivet
WARNING spring force is constantly ex- holes. Use No. 30 drill bit to drill two
erted to inhibit inadvertent brake holes in retainer.
application. Care must be taken as the
spring is engaged to prevent injury to (4). Cleco retainer assembly in place. Use
personnel or equipment damage. retainer as guide and use a No. 15 drill
bit to drill two holes into face of vertical
(7). Install lever with attached parts, and member. Remove handle retainer
spring on pin and secure with washer, assembly from vertical member.
nut, and new cotter pin. Engage free
end of spring under head of clevis pin. (5). Deburr holes and touch up with primer
(CM318).
F. Handle Retainer Assembly Installation
(6). Attach handle retainer assembly to
(Ref. Figure 901) The handle retainer assem- vertical member with four blind rivets.
bly must be installed on canted bulkhead 78.50
vertical member to secure the rotor brake G. Rivnut Installation
operating handle in the stowed (raised)
position. (Ref. Figure 902) A rivnut must be installed in
the main rotor mast pan as an attachment
point for one of the clamps used to secure
hydraulic tube assembly. For R/H rotor brake
Item Nomenclature
installation, a rivnut must be installed in the
canted bulkhead 78.50 vertical member for
CM318 Primer attachment of the hydraulic relief valve.
NOTE: The master cylinder linkage assembly Consumable Materials

must be installed so that the handle retain- (Ref. Section 910000)
er assembly can be positioned correctly. Item Nomenclature
(1). Position handle retainer assembly on CM318 Primer

canted bulkhead 78.50 vertical member
so that when rotor brake operating
Care must be taken when drill-
handle is in the stowed position, CAUTION ing the mast pan for rivnut in-
retainer clip engages handle just below
stallation to prevent damage to wiring har-
the rubber grip.
nesses which are installed on the upper side
To prevent damage to compo- of the pan, or to critical structure members
CAUTION nents, point of drill bit must not to which the pan is riveted. A drill stop or
be allowed to penetrate through wall of ver- other suitable means should be used to pre-
tical member more than 1/4 inch (6.35 mm). vent point of drill from penetrating more
than 1/4 inch (6.35 mm) into vertical mem-
NOTE: The tunnel beam web is secured to the ber.
vertical members by a series of rivets. Two
of these rivets must be removed and re- (1). Lay out location for hole in transmis-
placed by rivets that also attach the handle sion pan. Use 1/4 inch (6.35 mm) drill
retainer assembly. bit to drill hole through pan, deburr
hole, and touch up raw metal surfaces
(2). Mark two rivets on front of vertical with primer (CM318). Install rivnut in
member that most closely match accordance with standard shop practice
position of handle retainer assembly. and manufacturers instructions.
Page 905
632200 Revision 20
MAINTENANCE MANUAL
BOLT
WASHERS
BRAKE CALIPER
BLEED
SCREW
WASHERS
MOUNTING BRACKET
(369D25100 TRANSMISSION)
BRAKE CALIPER INSTALLATION

(369D25100 TRANSMISSION
INSTALLATION SHOWN)
MASTER CYLINDER INSTALLATION
G6320131B
Figure 902. Rotor Brake Installation (Sheet 1 of 2)
Page 906
Revision 20 632200
MAINTENANCE MANUAL
NUT
BLEEDSCREW
CLAMP
SCREW
WASHER TEE
RIVNUT
BLEEDSCREW
TEE
SPECIAL NUT
SHIM
CLAMP WASHER
SCREW COUPLING
WASHER
DISC
MASTER
CYLINDER
TACH
GENERATOR
HANDLE
ASSEMBLY
G6320132A
Figure 902. Rotor Brake Installation (Sheet 2 of 2)
Page 907
632200 Revision 20
MAINTENANCE MANUAL
(2). Lay out location for hole in vertical in tail rotor cover assembly for use as
member. Use 1/4 inch (6.35 mm) drill spacers. Position caliper mounting
bit to drill hole through outer face of bracket on studs and secure with
vertical member. Deburr hole and touch washers and nuts. Torque nuts to 50
up raw metal surfaces with primer. 70 inchpounds (5.65 7.91 Nm).
Install rivnut in accordance with
standard shop practice and manufac- (2). Secure installation with lockwire
turers instructions. (CM702).
H. Window Support Channel Modification J. Caliper Assembly, Brake Disc and Drive
Coupling Installation
(Ref. Figure 903) Three clamps are used to
attach hydraulic tube assembly to the window (Ref. Figure 902) The caliper assembly is
support channel. Modifications to the channel bolted to a mounting bracket which is installed
are required to accommodate two of the on the main transmission tail rotor cover. The
clamps. brake disc is bolted on the drive coupling
which is installed on the transmission output
shaft. For clarity, the brake disc and drive
Consumable Materials coupling are considered as a single item,
(Ref. Section 910000) herein referred to as the disc/coupling unit.
Item Nomenclature Although the caliper assembly and the
CM318 Primer disc/coupling unit are not mechanically
connected, they are installed on the transmis-
sion with the outer portion of the disc posi-
(1). Use 1/8 inch (3.175 mm) drill bit to tioned between the two halves of the caliper
remove one (3rd rivet from front) of the assembly. This arrangement makes it neces-
four rivets used to attach forward sary to install both units at the same time.
nutplate angle clip to channel. Enlarge
hole to 0.1880.218 inch (4.77525.5372
mm) with 3/16 inch (4.7625 mm) drill Consumable Materials
bit, deburr hole, and touch up raw (Ref. Section 910000)
metal surfaces with primer (CM318). Item Nomenclature
(2). Lay out location for hole in channel as CM117 Grease
shown. Use 3/16 inch (4.7625 mm) drill
to drill hole in channel, deburr hole, CM434 Thread sealant
and touch up raw metal surfaces with CM702 Lockwire CRES
primer.
I. Caliper Mounting Bracket Initial Axial positioning of the

Installation
WARNING drive coupling is critical as
it controls the mechanical interface be-
(Ref. Figure 902) The caliper mounting bracket tween the coupling and the tail rotor
is installed on four of the twelve studs used to drive shaft. Excessive axial loads can
secure the tail rotor cover assembly on the contribute to coupling failure which
main transmission housing. could result in injury to personnel or
equipment damage. Refer to Section
631510 for shimming procedures for
Consumable Materials installing coupling disc on shaft.
Item Nomenclature NOTE: Before installing caliper, brake disc and
CM702 Lockwire CRES drive coupling, install new tachometer gen-
erator and gasket. Ensure that mechanical
drive components are correctly engaged and
(1). Place three washers on each of the four electrical receptacle is at the 11 oclock posi-
studs (1, 2, 10, and 11 oclock positions) tion.
Page 908
Revision 20 632200
MAINTENANCE MANUAL
369D230125 REF
369D2301213 REF
G632019
Figure 903. Modifying Window Support Channel

(1). Measure (with a micrometer) and on tees, and install bleed screws in
record thickness of brake disc at four adapters. Remove and discard hard-
locations around the disc. Calculate and ware used to hold caliper halves
record average of thickness measure- together.
ments.
NOTE: The caliper assembly consists of two
(2). Position brake disc on tail rotor drive identical halves. When received, the halves
coupling with raised center side of disc are held together by commercial hardware.
seated firmly on shoulder of coupling This hardware is replaced by qualified stan-
and with bolt holes aligned. Secure disc dard hardware which also secures the cali-
to coupling with attaching hardware per assembly on the mounting bracket.
and torque nuts (in an alternating
sequence) to 100 140 inchpounds (5). Insert bolts through one caliper half,
(11.30 15.82 Nm). position assembled parts of mounting
(3). Measure (with an inside micrometer) bracket and screw bolts into bracket
and record gap between brake puck finger tight to maintain alignment of
faces. Subtract brake disc thickness caliper half. Use a Cclamp or other
calculated in step (1). from gap mea- suitable means to clamp caliper half
surement and divide the difference by firm against bracket.
two to determine the optimum puckto
disc clearance. (6). Coat, completely but sparingly, splines
of transmission output shaft with
(4). Remove bleed screws from ports in ends grease (CM117) and threads of coupling
of caliper assembly. Coat all but first with antiseize compound (CM113), or
two threads of bleed screws, tees, and equivalent. Install coupling/disc unit on
plugs with thread sealant (CM434). shaft and install bolt into end of shaft
Install plugs in bleed screw ports and to ensure that coupling is seated firmly
tees in caliper bodies, install adapters against shim washers on shaft.
Page 909
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MAINTENANCE MANUAL
TUBE ASSY
BAFFLE ASSY
MAST SUPPORT
GROMMET
PAN
NOTE: CHANNEL ASSY

LEFTHAND INSTALLATION
RIGHTHAND OPPOSITE G632020
Figure 904. Hydraulic Tube Installation
The caliper assembly must NOTE: Foreandaft positioning of the caliper

WARNING be installed so that caliper assembly, which determines the puckto
todisc clearances on both sides of disc disc clearance relationship, is established by
are approximately equal. Improper in- installing shim washers between the caliper
stallation can cause malfunctions assembly and the mounting bracket. Nine
which could result in injury to person- washers are provided for each attaching
nel or equipment damage. bolt; those not required for shimming must
be installed under the bolt heads.
(7). Measure gap between brake caliper (8). Remove bolts and place the correct
housing and forward face of disc with a number (nine less the number required
thickness gage. Subtract desired for shimming) of washers on each bolt.
calipertodisc clearance calculated in Insert bolts through caliper halves and
step (3). from this measurement to screw one bolt finger tight into mount-
determine amount of shimming (washing bracket. Release clamped caliper
ers) to be installed between caliper half and move it away from bracket,
assembly and mounting bracket. Divide place required number of shim washers
the difference by 0.032 inch (0.8128 on second bolt as it is pushed through
mm) (washer thickness) to determine caliper assembly, and screw bolt into
number of shim washers needed. bracket a few turns. Repeat procedure
Page 910
Revision 20 632200
MAINTENANCE MANUAL
to install shim washers on other bolt.

Tighten bolts firmly to secure installa-
tion. 4389 GRIP
(1 REQD)
(9). Check calipertodisc clearances with a
thickness gage. If clearances are
approximately equal, torque mounting
bolts to 160 190 inch pounds (18.08
21.47 Nm) and secure with lockwire
(CM702). Torque coupling bolt to 250
300 inchpounds (28.25 33.90 Nm)
plus drag torque.
MASTER
(10). After the rotor brake components have CYLINDER
been installed on the main transmis-
sion, the builtup unit must be in-
0.02 IN. (0.508 MM) GAP
stalled in the aircraft (Ref. Sec. 0.04 IN. (1.016 MM)
632000/25).
The main transmission must

WARNING be installed in the aircraft
with special care to avoid damage to
rotor brake components. Installation G632022A
damage could lead to system failure
which could result in injury to person- Figure 905. Positioning Master Cylinder
nel or equipment damage.
(3). Install new cap and reworked gasket on
(11). If tachometer generator is installed on master cylinder with attaching screws
transmission, connect electrical plug installed finger tight.
(P202) on aircraft wiring harness to
receptacle on tachometer generator. (4). Coat all but first two tapered pipe
threads of nipples and elbow with
thread sealant (CM434). Install nipples
K. Master Cylinder Assembly Initial in cap and elbow in master cylinder.
Installation
(5). Place one washer on each bolt, place
(Ref. Figure 902) The master cylinder assem- stop on bolts and insert bolts through
bly is mounted on the master cylinder linkage master cylinder. Place two washers on
assembly bracket. each bolt as spacers. Position as-
sembled parts on linkage assembly
bracket and secure installation with
Consumable Materials washers and nuts. Tighten nuts only
(Ref. Section 910000) finger tight.
Item Nomenclature
CM434 Thread sealant NOTE: Mounting holes in bracket are elon-
gated to enable lateral position adjustment
of master cylinder assembly.
(1). Remove attaching screws and vendor (6). With actuating handle in stowed
supplied cap from master cylinder. position, adjust position of master
Vendor cap is not used. cylinder assembly so that clearance
(measured with a thickness gage)
(2). Rework vendorsupplied gasket (Ref. between actuating lever (Ref.
Figure 906). Figure 905) and master cylinder piston
Page 911
632200 Revision 20
MAINTENANCE MANUAL
is 0.0200.040 inch (0.5081.016 mm). ing hardware loosely to hold clamps

Tighten nuts to hold master cylinder (and tube assembly) to pan and window
assembly firmly in position. channel.
L. Hydraulic Relief Valve Initial Installation (4). Connect tube assembly loosely to elbow
in master cylinder and to tee.
(Ref. Figure 902) The hydraulic relief valve is
attached by means of a clamp to the canted (5). With all tube assemblies and fittings
bulkhead 78.50 vertical member, and is connected, tighten nuts on tube assem-
connected hydraulically, by means of tube blies. Tighten attaching hardware for
assemblies, between the master cylinder all clamps.
assembly and the caliper assembly.
NOTE: It is not necessary to tighten tube as-
(1). Place new Oring on reducer and screw sembly nuts at this time. The tube assembly
reducer into relief valve. Connect relief will have to be removed to permit filling the
valve to tube assembly and tighten tube hydraulic system.
nut. Install clamp on relief valve.
(6). Connect tube assembly to nipple in
(2). Position assembled parts with relief master cylinder cap and tighten tube
valve in V of handle retainer assem- nut.
bly. Install attaching hardware loosely
to hold assembled parts on canted N. Rotor Brake Installation Servicing
bulkhead 78.50 vertical member.
After all operating components of the rotor
NOTE: Screw is threaded into nutplate for LH brake system have been installed, the hydrau-
installation, and into rivnut for RH installa- lic system must be filled with hydraulic fluid
tion. and have all entrapped air bled off. Refer to
Rotor Brake Hydraulic System Bleeding.
M. Hydraulic Tube Assemblies Initial
Installation 0.50 IN. (12.70 MM) DIA.
(Ref. Figure 902) Two tube assemblies are

installed to connect the master cylinder 0.56 IN. 0.56 IN.
assembly and the caliper assembly. (14.224 MM) (14.224 MM)
Item Nomenclature
CM418 Cement, epoxy
(1). Connect tee loosely to tube assembly.

Make straight radial cut into center
hole of grommet and install grommet
and clamps on tube assembly.
(2). Position assembled parts on window

channel so that grommet can be
engaged in slot of air baffle. Connect
tube assembly loosely to tee on caliper
assembly and connect tee loosely to
EXISTING HOLES
tube assembly on hydraulic relief valve. G632021A
(3). Bond grommet into air baffle slot with Figure 906. Reworking Master Cylinder
epoxy cement (CM418). Install attach- Gasket
Page 912
Revision 20 632200
MAINTENANCE MANUAL
O. Installing Interior Furnishings to be drilled on rotor brake forward

cover panel.
After the operating components of the rotor
brake installation have been checked out, the (3). Use No. 42 drill bit to drill holes at
various items of interior furnishings (trim marked location for attaching screws.
panels, cover assemblies, seats, etc.) and the
fuselage doors must be reinstalled. This NOTE: It may be more convenient to remove
includes those items that are specific for the convenience panel cover assembly while
rotor brake installation, and those that were drilling hole.
removed to permit access for installing the
rotor brake components. (4). On the 5000D, secure convenience
panel cover assembly with doublers to
P. Map Case Assembly Modification and angle assembly with attaching screw.
Installation On the others, the convenience panel
cover assembly will be permanently
(Ref. Figure 907) Before the map case assem- fastened down when mated with the
bly can be reinstalled, it must be modified to rotor brake forward cover assembly.
accommodate the rotor brake forward cover
assembly. R. Rotor Brake Forward Cover Assembly
Installation
(1). Mark map case panel for cutout. Use a
sharp knife to cut out marked area, (Ref. Figure 908) The rotor brake forward
taking special care to avoid cutting cover assembly mates with the convenience
outside of marked area. panel cover assembly to enclose and protect
the rotor brake components (master cylinder,
(2). Install map case assembly on canted
etc.) installed on the canted bulkhead 78.50
bulkhead 78.50 structure with three
structure. It is installed over the forward
attaching screws.
portion of the master cylinder assembly and
NOTE: A fourth screw will also be used to at- incorporates cutouts to accommodate the
tach the rotor brake forward cover assembly brakes handle and retaining clips.
(Ref. Figure 908).
(1). Position rotor brake forward cover
Q. Convenience Panel Cover Assembly assembly on map case assembly with
Modification and Installation aft edge overlapping forward edge of
convenience panel cover assembly and
(Ref. Figure 908) The convenience panel cover with brake and retaining clips extend-
assembly mates with the rotor brake forward ing through cutouts.
cover assembly to enclose and protect the rotor
brake components installed on the canted NOTE: If aircraft is equipped with optional
bulkhead 78.50 structure. particle separator, it may be necessary to
trim the forward cover assembly for clear-
(1). Position new convenience panel cover ance.
assembly with the aft edge overlapping
the forward edge of the transmission (2). On the 500D, mark location for hole in
cover panel. Install attaching screws to upper corner of forward cover assembly
hold panels in position. to line up with isolator mount, and in
lower corner to line up with nutplate in
(2). On the 500D, mark location for hole in angle assembly on canted bulkhead
the forward corner of convenience panel 78.50 shoulder beam. On the others,
cover assembly to line up with nutplate mark location for hole in upper corner
on angle assembly on canted bulkhead of forward cover assembly to line up
78.50 shoulder beam. On the others, with isolator mount and in upper and
mark location for holes in forward lower outboard corners to line up
corner of convenience panel cover parallel with holes previously drilled in
assembly to line up parallel with holes the convenience panel cover assembly.
Page 913
632200 Revision 20
MAINTENANCE MANUAL
3.00 IN. (7.62 CM)
27.25 IN.
(69.22 CM)
23.38 IN.
(59.39 CM)
18.25 IN.
(46.36 CM)
369E/FF
15.00 IN.
(38.10 CM)
9.87 IN.
(25.07 CM)
369D
G632015A
Figure 907. Modifying Map Case Panel
Page 914
Revision 20 632200
MAINTENANCE MANUAL
0.2200.226 IN. (5.5885.7404 MM)

DIA. HOLE TO MATCH MAP CASE
ASSEMBLY AND ISOLATOR
MOUNT
DRILL 0.2200.226 IN.
(5.5885.7404 MM)
DIA. HOLE (2 PLCS)
SHIM
3.00
2.00 IN.
(50.80 MM)
SHIM
1.50 IN.
(38.10 MM)
DRILL 0.2200.226 IN.

(5.5885.7404 MM)
DIA. HOLE (2 PLCS)
369E/FF
G6320181A
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 1 of 2)
Page 915
632200 Revision 20
MAINTENANCE MANUAL
DRILL 0.2200.226 IN. (5.5885.7404 MM)

DIA. HOLE TO MATCH NUTPLATE
DRILL 0.2200.226 IN. (5.5885.7404 MM)

DIA. HOLE TO MATCH MAP CASE
ASSEMBLY AND ISOLATOR MOUNT
NOTE:
LEFTHAND ROTOR BRAKE INSTALLATION SHOWN,
RIGHTHAND INSTALLATION OPPOSITE. G6320182A
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 2 of 2)
Page 916
Revision 20 632200
MAINTENANCE MANUAL
(3). Use No. 42 drill bit to drill holes at the outboard edge of forward cover
marked locations for attaching screws. assembly and convenience panel cover
assembly.
NOTE: It may be more convenient to remove
forward cover panel assembly while drilling (5). Push panel boot aft on brake handle
holes. approximately 2 inches (5.08 cm) and
secure boot fastener tape.
(4). Secure forward cover assembly and S. Weight and Balance
map case panel assembly with attach-
ing screws. On the 500D, install screw (Ref. Table 901) After installing the rotor
through nutplate in angle assembly. On brake, incorporate changes in helicopter
the others, install screws into shims on weight and balance record.
lb (kg) in. (cm) inlb (kgcm)
500D (left side)
Added +7.5 (+3.40) 106.6 (270.764) +800 (9216.96)
Removed 0.0 0.0
Changed +7.5 (+3.40) 106.6 (270.764) +800 (9216.96)
500D (right side)
Added +6.8 (3.08) 108.9 (276.606) +741 (8537.21)
Removed 0.0 0.0
Changed +6.8 (3.08) 108.9 (276.606) +741 (8537.21)
369E/FF 500N (left and right)
Added +7.5 (+3.40) 106.5 (270.51) +799 (9205.44)
Removed 0.0 0.0
Changed +7.5 (+3.40) 106.5 (270.51) +799 (9205.44)
600N (left and right)
Added +7.6 (+3.45) 98.4 (294.44) +748 (862.3)
Removed 0.0 0.0
Changed +7.6 (+3.45) 98.4 (294.44) +748 (862.3)

632200 Revision 20
MAINTENANCE MANUAL
Section
632510
Tail Rotor
Transmission (Two
and Four Blade)
(369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR TRANSMISSION (TWO AND FOUR BLADE)

1. Tail Rotor Transmission Do not carry or otherwise sup-
CAUTION port transmission by coupling,
(Ref. Figure 201) The tail rotor transmission is as coupling diaphragm may be permanently
a rightangle transmission with a magnesium distorted. During performance of all mainte-
alloy housing. A magnetic chip detector is nance on transmission, use extra care to
located on the aft end of the transmission, a keep contaminants such as paint, dirt, etc
breatherfiller is located on the top and a sight from areas around input and output shaft
gage is mounted on the aft end (twobladed) or seals.
on the right side (fourbladed) of the transmis-
sion. (1). Install tail rotor drive shaft on tail rotor
transmission (Ref. Sec. 631510).
2. Tail Rotor Transmission Replacement
(Ref. Figure 203) Ensure securi-
CAUTION ty of tail rotor transmission
A. Tail Rotor Transmission Removal
mount studs. Maximum allowable side play
(1). Disconnect tail rotor driveshaft from at end of stud is 0.004 inch (0.102 mm), max-
transmission (Ref. Sec. 631510). imum allowable axial play is 0.005 inch
(0.127 mm). For stud replacement, refer to
(2). Disconnect chip detector wire. the Structural Repair Manual (SRM).
(3). (369D/E) Remove four nuts and NOTE: Ensure all paint and sealant is removed
washers from transmission mount from mating surfaces. Remove excessive
studs. sealant, as required, from transmission to
gain clean mounting surfaces. Ensure that
(4). (369FF) Remove four bolts, eight no gap in sealant coverage exists around the
washers and four nuts between trans- transmission bearing cover assembly.
mission and tailboom extension.
(2). Visually inspect mounting studs for
NOTE: Retain any shimming washers that damage or deformation. Replace
may be between tail rotor transmission and damaged or deformed stud (Ref. SRM).
tail boom for transmission installation. (3). Apply primer (CM318) in holes, on
faying surfaces and on the grip area of
(5). With assistance, support transmission the mounting studs. Install tail rotor
and shaft in line for minimum deflec- transmission or tailboom extension
tion of coupling and remove tail rotor while primer is still wet.
drive shaft and transmission as a unit.
(4). With assistance, support transmission
(6). Remove tail rotor from tail rotor and shaft in line for minimum deflec-
transmission (Ref. Sec. 642000). tion of coupling and install tail rotor
drive shaft and transmission as a unit
(7). Remove tail rotor drive shaft from tail (Ref. Sec. 631510).
rotor transmission (Ref. Sec. 631510).
NOTE: Note the drag torque for each nut and
B. Tail Rotor Transmission Installation its location on the transmission in the heli-
copter for later use.
(a). (369D/E) Secure tail rotor transmis-
sion to four tailboom mounting studs
Item Nomenclature
with washers and nuts. Torque nuts
CM318 Primer to 75 95 inchpounds (8.47
Page 201
632510 Revision 36
MAINTENANCE MANUAL
TRANSMISSION COU-
PLING (BENDIX) (CAU-
TION: DO NOT LIFT AS- FAILSAFE
SEMBLY FROM COUPLING
FLANGE) BOLT
FAILSAFE SOCKET
COUPLING BOLT
BREATHER FILLER
OUTPUT SHAFT
COUPLING
(KAMATIC)
INPUT SHAFT
LIQUID LEVEL
PLUG
CHIP DETECTOR
2BLADED TAIL ROTOR TRANSMISSION
LIQUID LEVEL
PLUG
CHIP DETECTOR
4BLADED TAIL ROTOR TRANSMISSION
G632014
Figure 201. Tail Rotor Transmission Stripping/Buildup
Page 202
Revision 20 632510
MAINTENANCE MANUAL
(b). (369FF) Secure tail rotor transmis- measure hole diameter. Hole diameter
sion to tailboom extension with four to be 0.3120.313 inch (7.92487.9502
bolts, eight washers and four nuts. mm) (Ref. CSPCOM5 for bolt hole
Torque nuts to 75 95 inchpounds repair).
(8.47 10.73 Nm) plus drag
torque. (3). Check input shaft for:
(5). Apply torque stripe paint. (a). Axial play by moving shaft in and
out; transmission must be cold. Axial
(6). Between 2 and 10 hours of helicopter play is limited to 0.004 inch (0.102
operation (to allow parts to seat), check mm) maximum.
the torque of each mounting nut as
follows: (b). Measure runout; mark high and low
extremes on outer end of shaft with
(a). Using the drag torque previously grease pencil. Total indicated runout
measured and noted, apply a torque should be less than 0.002 inch (0.051
load of 75 95 inchpounds (8.47 mm).
10.73 Nm) plus the noted drag
torque (noted for each individual (4). Check output shaft for:
nut) to each mounting nut of the (a). Axial play; no axial movement is
transmission. permitted.
(b). Reapply torque stripe paint. (b). Measure runout; mark high and low
extremes on outer end of shaft with
(7). Install tail rotor on tail rotor transmis-
grease pencil. Total indicated runout
sion (Ref. Sec. 642000).
should be less than 0.0025 inch
(8). Connect chip detector wire. Torque nut (0.0635 mm).
to 12 15 inchpounds (1.36 1.69 (5). While gently pulling out on input shaft,
Nm). check gearset backlash:
(9). Connect tail rotor drive shaft to main (a). Twobladed gearset backlash should
transmission (Ref. Sec. 631510). be 0.0040.008 inch (0.1020.203
(10). Drain residual preservative oil and mm).
service transmission with lubricating (b). Fourbladed gearset backlash should
oil (Ref. Sec. 120000). be 0.00250.0050 inch (0.06350.127
mm).
3. Tail Rotor Transmission Inspection
NOTE: Although not required, placing marks
(Ref. Figure 201) on end of output shaft provides guides for
NOTE: If following inspections reveal damage, subsequent installation of tail rotor assem-
repair according to instructions in CSP bly in a manner that reduces chances of
COM5. high frequency vibrations and lessens possi-
bility of requirement for tail rotor balancing.
(1). Check transmission for leaks, cracks
and corrosion. To evaluate oil leakage, (6). Inspect all scoring or scratching of
refer to Fluid Leak Analysis (Ref. Sec. output shaft to determine if marks
120000). penetrate through cadmium plating
and into steel shaft. Penetration of steel
(2). Inspect Sta. 284 bellcrank hole for shaft is allowable to maximum depth of
elongation; if elongation is suspected, 0.010 inch (0.254 mm).
Page 203
632510 Revision 40
MAINTENANCE MANUAL
BREATHERFILLER
LIQUID LEVEL PLUG
(4BLADED T/R) BREATHERFILLER
ORING
ORING
ADAPTER
ORING
ORING
LIQUID
LEVEL PLUG
(2BLADED T/R)
INPUT SHAFT
OUTPUT SHAFT
0.046 IN. (1.1684 MM) 0.10 IN. (2.54 MM) LET-

LINEWIDTH (TYP) TER HEIGHT (TYP)
DRAIN HOLE
FULL
0.406 IN. (10.3124 MM) ADD
AXIS OUTPUT SHAFT BREATHER HOLE

0.06 IN.
(1.524 MM)
BREATHERFILLER
LIQUID LEVEL PLUG MARKINGS
INPUT SHAFT
OUTPUT SHAFT
85
85
BREATHER HOLE ORIENTATION

G632016A
Figure 202. Replacement of Liquid Level Plug and BreatherFiller
Page 204
Revision 20 632510
MAINTENANCE MANUAL
4. Tail Rotor Transmission Stripping 6. Tail Rotor Transmission Parts

Replacement
(Ref. Figure 201) Stripping of the tail rotor
transmission is not required following its (Ref. Figure 202)
removal from the helicopter. Perform the
following stripping procedure if in preparation Consumable Materials
for transmission shipment or storage only. (Ref. Section 910000)
Item Nomenclature
Consumable Materials CM114 Petrolatum
(Ref. Section 910000) CM222 1,1,1Trichloroethane
Item Nomenclature CM311 Coating, logo white / Thinner
CM208 Barrier material CM702 Lockwire CRES
(1). Remove coupling bolt and coupling from NOTE: Replace liquid level plug, chip detector
input shaft. and breatherfiller using torque values in
following paragraphs. Lubricate mating
NOTE: For tail rotor transmission replace- bores of Orings with petrolatum (CM114)
ment, further stripping is not required. A re- to prevent damage to Orings. Repair other
placement transmission is equipped with all components or replace tail rotor transmis-
other accessories. sion oil seals (Ref. COM).
(2). Drain oil from transmission (Ref. Sec. (1). Chip Detector Torque valve body 50
120000). Residual operating lubri- 60 inchpounds (5.65 6.78 Nm);
cant is approved internal preservative detector 40 50 inchpounds (4.52
for shipping or storage. 5.65 Nm). Safety with lockwire
(CM702).
(3). Wrap transmission in barrier material
(CM208) to protect shaft splines and (2). Liquid Level Plug Torque liquid level
chip detector stud during handling, plug to 50 60 inchpounds (5.65
shipping or storage. 6.78 Nm). If levellines and lettering of
liquid level plug cannot be made
5. Tail Rotor Transmission Buildup parallel with axis of transmission
output shaft when plug is torqued
(Ref. Figure 201) within 50 60 inchpound (5.65 6.78
Nm) range, clean glass by firmly
Consumable Materials rubbing with soft cloth, then mix white
(Ref. Section 910000) coating (CM311) with equal amount of
Item Nomenclature thinner and apply lines and lettering.
Safety with lockwire.
CM112 Antiseize compound high temperature NOTE: Some models use an adapter with an
additional Oring. On those models, install
adapter with Oring, then install breather
(1). Coat coupling splines with grease filler.
(CM111) and coupling bolt threads with
antiseize compound (CM112) before (3). Oil BreatherFiller Torque breatherfil-
reassembly. ler to 45 55 inchpounds (5.08
6.21 Nm). If equipped with a 369A5429
(2). Install coupling and bolt. Torque breather, hole in breather filler must be
coupling bolt to 250 300 inch directed rearward at final torque.
pounds (28.25 33.90 Nm) plus drag Locating vent at any angle aft of output
torque. Check coupling bolt for drag shaft centerline (viewed from above)
torque serviceability of 25 inch adequately directs vent rearward. One
pounds (2.82 Nm) minimum, 200 or two washers may be added between
inchpounds (22.60 Nm) maximum. Oring and breather flange (one washer
Page 205
632510 Revision 20
MAINTENANCE MANUAL
changes orientation by approximately (3). If contact occurs, rework tail rotor

100 degrees). Safety with lockwire. transmission housing as follows:
NOTE: If oil breatherfiller assembly becomes (a). Chamfer the web on transmission
clogged, use light air pressure, approxi- housing to dimensions shown in
mately 5 psig (34 kPa) or a 0.125 inch (3.175 Figure 204.
mm) dia. rod applied into the threaded end Do not remove material in
to dislodge debris. Ultrasonically clean WARNING excess of specified dimen-
breather in solvent (CM222) for ten min- sion.
utes.
(b). Blend chamfer into existing radius at
7. Input and Output Gearshaft Cover Oil the bottom and radius it at the top.
Leak Repair Width of chamfer must be
0.0600.090 inch (1.5242.286 mm).
Repair oil leaks at input and output gearshaft
cover by installing a protective sleeve (Speedi (c). Apply surface touchup treatment
Sleeve) on the gearshaft area contacted by the (Ref. Sec. 203000).
oil seal lip (Ref. COM). (4). Record compliance of this rework in the
aircraft logbook.
8. Tail Rotor Transmission Housing
Assembly Rework (PN 369D25401) AXIAL PLAY 0.005 IN.
(0.127 MM) MAX
(Ref. Figure 204) An interference condition
may exist between the tail rotor transmission
housing and the tail rotor control bellcrank
SIDE PLAY 0.004 IN.
with the tail rotor pedal at extreme right (0.102 MM) MAX
position. The following procedure provides
inspection criteria and rework instructions, if
necessary, for the tail rotor transmission
housing to correct this condition should it
exist.
(1). With assistance, depress and hold right

tail rotor pedal to extreme right
position and inspect web area of tail
rotor transmission housing that comes
in close contact with tail rotor control
bellcrank. If adequate clearance exist
between transmission housing and
control bellcrank, no rework action is
necessary. G632023A
(2). Sign off aircraft logbook to indicate Figure 203. Tail Rotor Transmission Mount
completion of this inspection. Stud Limits
Page 206
Revision 20 632510
MAINTENANCE MANUAL

A
0.350 IN. (8.89 MM) MIN.

A
REWORK AREA
(END VIEW)
0.500 IN.
(12.70 MM)
R
0.0600.090 IN.
REWORK AREA (1.5242.286 MM) X 45
OUTPUT SHAFT BLEND INTO EX-

ISTING RADIUS TAIL ROTOR
HOUSING AS-
SEMBLY
G632017A
Figure 204. Rework of Tail Rotor Transmission Housing Assembly

632510 Revision 20
MAINTENANCE MANUAL
Section
632530
NOTARr
AntiTorque System
Fan Transmission
(500/600N)
MAINTENANCE MANUAL
NOTAR ANTITORQUE SYSTEM FAN TRANSMISSION

1. Fan Transmission B. Fan Transmission Installation
The function of the fan transmission is to step (Ref. Figure 201)
up RPM from the main transmission output to
the fan via fan drive shaft, gears, and intercon- Do not carry or support trans-
CAUTION mission by coupling as damage
nect shaft. The transmission housing is made
of magnesium, and contains input and output can occur to coupling. During performance
gear shafts, two angular contact bearings, of maintenance on transmission, use extra
coupling, seals, packings, output cover assy, care to keep contaminants such as paint,
chip detector, sight glass, and oil breather dirt etc from areas around input and output
assembly. shaft seals.
2. Fan Transmission Replacement (1). Install fan drive shaft (Ref. Sec.
631530).
Remove and install fan transmission according
to the following procedures. (2). Locate and align transmission with
mounting holes on helicopter. Install
A. Fan Transmission Removal four bolts and washers on transmission.
Torque bolts to 70 90 inch pounds
(Ref. Figure 201) (7.90 10.17 Nm); torquestripe bolts.
(1). Remove inlet screen, inlet fairing,
(3). Connect previously identified chip
engine plenum access cover, and fan
detector wires.
hub transmission fairing (Ref. Sec.
533030). (4). Remove cap and connect drain line on
(2). Remove tailboom (Ref. Sec. 534030). elbow at bottom of transmission.
(3). Drain fan transmission of oil. Discon- (5). Install fan interconnect shaft (Ref. Sec.
nect drain line and cap elbow at bottom 631530).
of transmission. (6). Install fan pitch control rod (Ref. Sec.
(4). Remove fan drive shaft (Ref. Sec. 672030).
631530). (7). Drain any residual preservative oil (if
(5). Remove fan pitch control rod (Ref. Sec. new transmission) and service with
672030). lubricating oil (Ref. Sec. 120000).
(6). Remove fan interconnect shaft (Ref. (8). Install fan hub transmission fairing
Sec. 631530). (Ref. Sec. 533030).
NOTE: Identify chip detector wires for future (9). Install engine plenum access cover (Ref.
reinstallation. Sec. 533030).
(7). Disconnect chip detector wires. (10). Install engine inlet fairing (Ref. Sec.
533030).
(8). Remove four transmission mounting
bolts, washers, and transmission from (11). Install inlet screen (Ref. Sec.
helicopter. 533030).
Page 201
632530 Revision 36
MAINTENANCE MANUAL
BOLT
(4 PLS)
WASHER
(4 PLS)
FAN TRANSMISSION
SUPPORT ASSY
FAN TRANSMISSION
BULKHEAD
G632024
Figure 201. Fan Transmission Removal/Installation
Page 202
Revision 20 632530
MAINTENANCE MANUAL
3. Fan Transmission Inspection NOTE: Replace liquid level plug, chip detector,
and breather assy using torque values in the
(1). Check transmission for leaks, cracks, following paragraphs. Lubricate O-rings
and corrosion. To evaluate oil leakage with petrolatum (CM114) to prevent dam-
refer to Component Fluid Leak Analy- age to O-rings. Repair other components or
sis (Ref. Sec. 120000). For further replace transmission oil seals if required
inspection criteria, please contact (Ref. COM).
MDHC Customer Support Department.
4. Tube Support Inspection (1). Chip Detector Torque valve body (large
hex) to 50 60 inch pounds (5.65
(1). Inspect mount bolts for security and 6.78 Nm) or 40 50 inch pounds
corrosion, lockwire intact. (4.52 5.65 Nm) (smaller hex).
(2). Inspect tube support for dents,
scratches, nicks, gouges and corrosion, (2). Liquid Level Plug Torque liquid level
none allowed. plug to 50 60 inch pounds (5.65
6.78 Nm). If level lines and lettering of
(3). Inspect for visible step in splined area. liquid level plug cannot are not parallel
with axis of transmission output shaft
(4). If step is evident: when torqued within 50 60 inch
(a). Measure between splines using pound (5.65 6.78 Nm) range, clean
0.0864 in. (2.19456 mm) diameter glass by firmly rubbing with soft cloth,
pins. then mix white coating (CM311) with
equal amount of thinner and apply
(b). Maximum measurement between lines and lettering. Safety with lockwire
pins is 0.390 in. (9.906 mm). (CM702).
5. Fan Transmission Parts Replacement
(3). Oil Breather Assy Torque breather
(Ref. Figure 202) assy to 45 55 inch pounds (5.08
6.21 Nm). Ensure breather hole is
facing up. Safety with lockwire
(CM702).
Item Nomenclature
CM114 Petrolatum
NOTE: If oil breather assy becomes clogged,
use light air pressure, approximately 5 psig
CM222 1,1,1Trichloroethane (34 kPa) or a 0.125 inch (3.175 mm) dia. rod
CM311 Coating, logo white / Thinner applied into the threaded end to dislodge de-
CM702 Lockwire CRES bris. Ultrasonically clean breather in sol-
vent (CM222) for ten minutes.
Page 203
632530 Revision 33
MAINTENANCE MANUAL
BREATHER
ORING
CHIP
DETECTOR
VALVE
LIQUID
LEVEL
PLUG ORING
ORING
VALVE
ORING
0.10 IN. (2.54 MM)

LETTER HEIGHT (TYP)
0.046 IN.
(1.1684 MM)
LINE WIDTH
(TYP)
AXIS OUTPUT SHAFT
0.406 IN. ROTATED VIEW

(10.3124 MM)
0.060 IN. LIQUID LEVEL PLUG MARKINGS

(1.524 MM) G632025A
Figure 202. Fan Transmission Parts Replacement
Page 204
Revision 20 632530
MAINTENANCE MANUAL
Section
633000
Main Rotor Static
Mast (369D/E/FF
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR STATIC MAST

1. Main Rotor Static Mast (1). Apply silicone sealant (CM430) on
bottom surface of mast tube and base at
(Ref. Figure 201) The main rotor mast provides drive shaft opening to seal base to mast
support for the main rotor, main transmission support structure at installation.
and drive shaft, and consists of an assembled
machined steel tube with a machined alumi-
num forged base. (2). Position main rotor mast so that holes
in base align with holes in mast support
2. Main Rotor Static Mast Replacement structure.
(369D25100 Transmission Installation)
A. Main Rotor Static Mast Removal (3). Install holddown bolts, washers and
(369D25100 Transmission Installation) mast mounting nuts; torque nuts to 700
820 inchpounds (79.09 92.65
(Ref. Figure 201) Nm).
Main rotor mast is highly
CAUTION stressed. Do not allow tools to (4). Check underside of mast support
strike mast or mast to strike any object. Any structure at left aft stud hole location.
impact damage may require replacement of Studtopan doubler surface must be
mast. clean to bare metal for electrical
bonding. Install main transmission
(1). Remove main rotor hub (Ref. Sec. mounting studs, plate spacers and nuts.
622000/60). Torque studs to 160 190 inch
pounds (18.08 21.47 Nm).
(2). Remove main rotor controls (Ref. Chap.
67).
(5). Using 0.00100.0015 inch
(3). Remove main transmission (Ref. Sec. (0.2540.0381 mm) feeler gage, check
632000/25). for gap between selflocking nuts and
plate spacers. No gap is allowed.
(4). Remove four studs, washers and nuts.
NOTE: Nuts securing studs have lefthand (6). If gap exists, remove nut and replace
threads. with new selflocking nut. Torque studs
into replacement nuts to 160 190
(5). Remove shaft support holddown nuts,
inchpounds (18.08 21.47 Nm) and
washers and bolts.
repeat step (5). above. Continue until
(6). Lift main rotor mast from helicopter. each nut is flush against its spacer.
Seal bare bond area with clear lacquer
B. Main Rotor Static Mast Installation (CM306).
(369D25100 Transmission Installation)
(Ref. Figure 201) (7). Install main transmission (Ref. Sec.
632000/25).
(Ref. Section 910000) (8). Install main rotor controls (Ref. Chap.
Item Nomenclature 67).
CM306 Lacquer, clear
CM430 Sealant, solvent resistant (9). Install main rotor hub (Ref. Sec.
622000/60).
Page 201
633000 Revision 20
MAINTENANCE MANUAL
HUB SLEEVE BEARING

SURFACE
MAIN ROTOR MAST
NUT (LEFT PLATE

HAND SPACER
THREADS)
TAPE
MAST BASE
RIVET
MAST SUPPORT
STRUCTURE PAN
NOTE 2
DRAIN
HOLE
MAST SUPPORT FITTING
MAST MOUNTING
NUT
MAIN TRANSMISSION
MOUNTING STUD
NOTE 1
AFT BULKHEAD
CHANNEL
TUNNEL BEAM WEB
TUNNEL BEAM WATERLINE 34.00

SIDECHANNEL
WATERLINE 45.36
NOTES:
1. THIS STUD REQUIRES ELECTRICAL BOND TO STRUCTURAL PAN.
2. MAIN ROTOR MAST IS SEALED TO STRUCTURE PAN (INSIDE MAST
TUBE AT BASE) WITH SILICONE RUBBER (CM430).
G633000A
Figure 201. Main Rotor Mast and Support Structure (369D25100 Transmission Installation)
Page 202
Revision 20 633000
MAINTENANCE MANUAL
3. Main Rotor Static Mast Replacement (4). Using 0.00100.0015 inch

(369F5100 Transmission Installation) (0.02540.0381 mm) feeler gage, check
for gap between selflocking nuts and
(Ref. Figure 202) plate spacers. No gap is allowed.
A. Main Rotor Static Mast Removal (5). If gap exists, remove nut and replace
(369F5100 Transmission Installation) with new selflocking nut. Torque bolts
into replacement nuts to 160 190
Main rotor mast is highly inchpounds (18.08 21.47 Nm) plus
CAUTION stressed. Do not allow tools to drag torque and repeat step e. above.
strike mast or mast to strike any object. Any Continue until each nut is flush against
impact damage may require replacement of its spacer. Seal bare bond area with
mast. clear lacquer (CM306).
(1). Remove main rotor hub (Ref. Sec. (6). Install main transmission (Ref. Sec.
6220). 6325).
(2). Remove main rotor controls (Ref. Sec. (7). Install main rotor controls (Ref. Sec.
6710). 6710).
(8). Install main rotor hub (Ref. Sec.
(3). Remove main transmission (Ref. Sec. 6220).
6325).
4. Main Rotor Static Mast Inspection and
(4). Remove four bolts, washers and nuts. Repair
(5). Lift main rotor mast from helicopter. (Ref. Figure 203)
B. Main Rotor Static Mast Installation
(369F5100 Transmission Installation) Consumable Materials
Item Nomenclature
Item Nomenclature CM234 Solvent, drycleaning
CM235 Cleaner
CM306 Lacquer, clear
CM304 Enamel, epoxy
CM305 Lacquer, acrylic
CM318 Primer
(1). Apply silicone sealant (CM430) on CM323 Primer
bottom surface of mast tube and base at CM713 Tape, pressure sensitive
drive shaft opening to seal base to mast
support structure at installation.
CM803 Crocus cloth
(2). Position main rotor mast so that holes
in base align with holes in mast support
structure. (1). Inspect all areas of main rotor mast for
cracks, nicks, scratches and evidence of
(3). Check underside of mast support impact damage.
structure at left aft stud hole location. (2). Inspect bearing surfaces for scoring and
Studtopan doubler surface must be galling.
clean to bare metal for electrical
bonding. Install main transmission (3). Inspect threads for damage.
mounting bolts, plate spacers and nuts.
Torque nuts to 160 190 inchpounds (4). Inspect rivets that secure base to mast
(18.08 21.47 Nm) plus drag torque. tube for security.
Page 203
633000 Revision 36
MAINTENANCE MANUAL
(5). Check that tape (Ref. Figure 201) on (b). Remove main transmission (Ref. Sec.
forward edge of mast tube is secure and 632000 or 632025, Main Trans-
undamaged; replace if defective. mission Replacement).
(a). Peel defective tape from mast. (c). Remove static mast (Ref. Main Rotor
(b). As required, polish area to remove Static Mast Replacement).
burrs and sharp areas with abrasive
cloth (CM802) or crocus cloth (d). Thoroughly clean interior tube with
(CM803). Solvent (CM234).
(c). Clean mast thoroughly with cleaner (e). Inspect for any corrosion, none
(CM235) and allow to dry. allowed.
(d). Apply primer (CM318) and paint (f). Remove paint from bad areas and
(CM305) to affected area. lightly feather paint edge with crocus
(e). Apply pressure sensitive tape cloth (CM803), remove any residue
(CM713) to mast. from feathering.
NOTE: To inhibit corrosion of mast when oper- (g). Apply primer (CM318), or (CM323),
ating in salt water environment, check tape to repair areas.
at frequent intervals. Also, apply thin
grease film (CM115) to bearing journals. (h). Allow to cure per manufacturers
instructions.
(6). Inspect internal bore for paint chipping,
orange peeling or flaking, none allowed. (i). Apply white paint (CM304) to
internal bore of mast.
NOTE: Chipping, orange peeling or flaking
paint will normally be at the base of the (j). Allow to cure per manufacturers
static mast tube. instructions.
(7). Reapply finish to mast internal bore
as follows: (k). Reinstall static mast.
(a). Remove main rotor hub (Ref. Sec. (l). Reinstall main transmission.
622000 or 622060, Main Rotor
Hub Replacement). (m). Reinstall main rotor hub.
Page 204
Revision 36 633000
MAINTENANCE MANUAL
HUB SLEEVE
BEARING SURFACE
NUT
MAIN ROTOR MAST

PLATE SPACER
TAPE
MAST BASE
RIVET
DRAIN HOLE
NOTE 2
MAST SUPPORT
STRUCTURE PAN
MAST SUPPORT
FITTING
MAST MOUNT BOLT

(NOTE 1)
NOTES:
1. THIS BOLT REQUIRES ELECTRICAL BOND TO STRUCTURAL PAN.
2. MAIN ROTOR MAST IS SEALED TO STRUCTURE PAN (INSIDE MAST
TUBE AT BASE) WITH SILICONE RUBBER (CM430).
6G63034
Figure 202. Main Rotor Mast and Support Structure (369F5100 Transmission Installation)
Page 205
633000 Revision 29
MAINTENANCE MANUAL
MAXIMUM REMOVAL
AREA REPAIRABLE OF
DAMAGE REPAIR PROCEDURE
MATERIAL (DEPTH)
POLISH DEFECTIVE AREA SMOOTH WITH

CORROSION AND 0.010 IN. ABRASIVE CLOTH (CM802 AND CM803) IF
SCRATCHES (0.254 MM) CADMIUM PLATING HAS BEEN PENE-
TRATED. TREAT REWORKED AREA WITH
PRIMER (CM318).
CHIPPING OF CAD- THICKNESS OF CAD- POLISH AREA SMOOTH WITH ABRASIVE

MIUM PLATING MIUM PLATING (0.0035 CLOTH (CM802 AND CM803). TREAT RE-
IN. (0.0889 MM MAXI- WORKED AREA WITH PRIMER (CM318)
MUM) AND LACQUER (CM306).
LONGITUDINAL
SCRATCHES THAT
DO NOT PENE-
TRATE THROUGH
NICKEL PLATE. MUST NOT PENE-
SCRATCHES MUST TRATE NICKEL PLAT-
POLISH AREA WITH ABRASIVE CLOTH
BE A MINIMUM OF ING, 0.0030.007 IN.
(CM802 AND CM803) TO REMOVE BURRS
0.25 IN. (6.35 MM) (0.0760.178 MM)
AND SHARP EDGES ONLY.
APART. RADIAL THICK
SCRATCHES ARE
NOT PERMITTED.
MUST NOT PENETRATE

THICKNESS OF SILVER
PLATING BY AN AREA
NO LARGER THAN 0.5
IN.2 (3.2258 CM2). NO
MORE THAN TWO
SUCH AREAS NO WIPE AREA CLEAN USING CHEESE CLOTH
CORROSION AND CLOSER THAN 1.5 IN. (CM820) DAMPENED IN SOLVENT (CM222).
SCRATCHES (3.81 CM) APART MAY SPRAY UNIFORM COATING, 0.0020.005 IN.
EXIST. IF WEAR EX- (0.0510.127 MM) THICK, ON WORN AREA
CEEDS LIMITS, CON- WITH LUBRICANT (CM103).
AREA EN- TACT MDHS WARRAN-
CLOSED TY REPAIR DEPART-
BY MAST MENT FOR REWORK
BASE DISPOSITION. ONLY
MDHS CAN PERFORM
PLATING REPAIRS.
REMOVE DEFECTIVE TAPE. POLISH DE-

FECTIVE AREAS TO REMOVE BURRS AND
CORROSION AND SHARP SURFACES WITH ABRASIVE
REPLACEMENT OF 0.010 IN.
CLOTH (CM802 AND CM803). TOUCH UP
TAPE. (0.254 MM)
REWORKED AREAS WITH PRIMER (CM318)
AND LACQUER (CM305). REPLACE TAPE
(CM713).
NOTE: FOR MAGNETIC PARTICLE INSPECTION,

REMOVE PAINT FROM APPLICABLE SURFACE
G633001B
Figure 203. Main Rotor Mast Inspection and Repair
Page 206
Revision 36 633000
MAINTENANCE MANUAL
Chapter
64
AntiTorque
Assembly
MAINTENANCE MANUAL
TABLE OF CONTENTS
640000 AntiTorque Assembly (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Tail Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. AntiTorque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Tail Rotor and Vibrations . . . . . . . . . . . . . . . . . . . . . . . 101
640005 FourBladed Tail Rotor Assembly Initial Installation (369D/E) . . . . . . . A
1. FourBladed Tail Rotor Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Tail Rotor and Transmission Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Existing Tail Rotor and Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. FourBladed Tail Rotor Transmission BuildUp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Drive Shaft, Tail Rotor Transmission and Tail Rotor Installation . . . . . . . . . . . . . 901
Figure 901. Tail Rotor Index Stripe Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 902
E. Tail Rotor Control OverCenter Trim System Rework . . . . . . . . . . . . . . . . . . . . . . . 903
F. TwoBladed OverCenter Trim System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
G. FourBladed Over Center Trim System Initial Installation . . . . . . . . . . . . . . . . . . 903
Figure 902. Over Center Trim System Installation . . . . . . . . . . . . . . . . . . . . . . . . . 904
H. FourBladed Tail Rotor Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
I. Horizontal Stabilizer Tip Weight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
J. N2 and NR (Rotor) Tachometer Indicator Replacement . . . . . . . . . . . . . . . . . . . . . 906
K. FourBladed Tail Rotor System Completion of Installation . . . . . . . . . . . . . . . . . . 906
L. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. Bracket Installation Sta. 78.50 Canted Wall . . . . . . . . . . . . . . . . . . 908
641000 Tail Rotor Blades (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Blade Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Abrasion Strip Dye Penetrant and Tap Test Inspection . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tail Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Inspection of Tail Rotor Blade Abrasion Strip . . . . . . . . . . . . . . . . . . . 203
4. Tail Rotor Blade Tip Cap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Installation of Tip CapToTail Rotor Blade Rivets . . . . . . . . . . . . . . 205
5. Tail Rotor Blade Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Tail Rotor Abrasion Strip Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Tail Rotor Blade Abrasion Strip Riveting . . . . . . . . . . . . . . . . . . . . . . . 208
Page i
MAINTENANCE MANUAL

7. Tail Rotor Blade Abrasion Strip Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8. Tail Rotor Blade Protective Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 205. Tail Rotor Blade Abrasion Strip Modification . . . . . . . . . . . . . . . . . . . 211
9. Tail Rotor Blade Leading Edge Crack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
A. Tail Rotor Blades with NewStyle Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Tail Rotor Blades with OldStyle Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 206. Tail Rotor Blade Leading Edge Crack Inspection . . . . . . . . . . . . . . . . 214
642000 Tail Rotor Hub and Fork (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Hub and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Hub and Fork Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tail Rotor Hub and Fork Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tail Rotor Hub and Strap Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Tail Rotor Hub and Fork Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Hub and Fork Assembly Installation (TwoBladed) . . . . . . . . . . . . . . 204
Figure 203. Hub and Fork Assembly Installation (FourBladed) . . . . . . . . . . . . . 205
3. Tail Rotor Hub and Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Conical Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Elastomeric Fork Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 204. Blade Flapping Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Elastomeric Bearing Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
642530 AntiTorque Fan (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. AntiTorque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. AntiTorque Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. AntiTorque Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. AntiTorque Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. AntiTorque Fan Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. AntiTorque Fan Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. AntiTorque Fan Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. AntiTorque Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4. Fan Blade Strap and Pitch Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Fan Blade Strap and Pitch Horn Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Fan Blade Strap and Pitch Horn Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Page ii
MAINTENANCE MANUAL

5. Retention Plate and Pitch Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Retention Plate and Pitch Plate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Retention Plate and Pitch Plate Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
6. Support Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Support Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Support Shaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7. Fan Balance Stud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Fan Balance Stud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fan Balance Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. AntiTorque Fan Support Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
8. Pitch Horn Counterweight Set Screw Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Pitch Horn Counterweight Set Screw Replacement . . . . . . . . . . . . . . 407
1. AntiTorque Fan Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Support Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. AntiTorque Fan Liner (Felt Metal Seal) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Fan Blade Inspection (100Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
5. Fan Pitch Slider Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. AntiTorque Fan Liner (Felt Metal Seal) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 801
A. AntiTorque Fan Liner (Felt Metal Seal) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. AntiTorque Fan Liner (Felt Metal Seal) Installation . . . . . . . . . . . . . . . . . . . . . . . 801
C. AntiTorque Fan Liner (Felt Metal Seal) Machining . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. AntiTorque Fan Liner (Felt Metal Seal) . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802. AntiTorque Fan Liner Felt Metal Seal Machining . . . . . . . . . . . . . . 803
2. AntiTorque Fan Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 803. Fan Bearing Regreasing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 804. Fan Bearing Regreasing Tool (ST614) . . . . . . . . . . . . . . . . . . . . . . . . . . 807
643000 Tail Rotor Pitch Control Assembly (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Pitch Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Pitch Control Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tail Rotor Pitch Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Pitch Control Assembly Wobble Check . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 202. SwashplatetoPitch Control Housing Clearance . . . . . . . . . . . . . . . 202
B. Tail Rotor Pitch Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Page iii
MAINTENANCE MANUAL

3. Tail Rotor Pitch Control Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 203. Tail Rotor Pitch Control Assembly (TwoBladed) . . . . . . . . . . . . . . . . 203
Figure 204. Tail Rotor Pitch Control Assembly (FourBladed) . . . . . . . . . . . . . . . 204
4. Tail Rotor and Pitch Control Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Tail Rotor Pitch Control Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Tail Rotor Blade Stop Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Tail Rotor Pitch Control Link Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Tail Rotor Conical Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9. Tail Rotor Pitch Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10. Tail Rotor Swashplate Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 205. Tail Rotor Swashplate Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . 207
Figure 206. Tail Rotor Swashplate Bearing Regreasing Tool . . . . . . . . . . . . . . . . . 208
Figure 207. Tail Rotor Swashplate Holding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 208. Tang Washer Inspection and Application of Torque Stripe . . . . . . . . 210
Page iv
MAINTENANCE MANUAL
Section
640000
AntiTorque
Assembly
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
ANTITORQUE ASSEMBLY
FAULT ISOLATION
1. Tail Rotor Assembly quickrelease pins on top of pedal arms and
repositioning pedals.
The tail rotor, mounted on the tail rotor
transmission at the end of the tailboom, The twobladed tail rotor assembly consists
counteracts main rotor torque and controls mainly of two tail rotor blades, a hub, drive
heading of the helicopter. The tail rotor control fork, two pitch control links, and a pitch
system changes the pitch of the tail rotor control assembly.
blades. The antitorque pedals move a system
of bellcranks and control rods routed through The fourbladed tail rotor assembly consists
the fuselage and tailboom to a pitch control of four tail rotor blades, two hubs, drive fork,
assembly which moves links that attach to four pitch control links and a pitch control
bladepitch arms on the blades. assembly. The blades are held together on the
hub by a laminated tensiontorsion strap pack
The pitch control assembly slides axially on that permits the blades to rotate axially on the
the tail rotor transmission output shaft. hub. The hub pivots in the drive fork. Control
Pushing forward on the left pedal changes of blade pitch is from the pitch control assem-
heading to the left; forward right pedal bly through pitch control links that connect to
movement changes heading to the right. pitch arms on the blade root fittings.
For twobladed tail rotor system, blade pitch
movement is 13 degrees to 15 degrees thrust 2. AntiTorque Fan Assembly
to the left and +27 degrees to +29 degrees to
the right. The antitorque fan is an axial fan with
thirteen variable pitch blades. The fan
For fourbladed tail rotor system, blade pitch provides antitorque by furnishing variable
movement is 13 degrees to 15 degrees thrust flow of low pressure high volume air through
to the left, +31 degrees to +32 degrees thrust the tailboom and thrusters.
to the right and +6.5 degrees to +8.5 degrees
thrust to the right at neutral. During flight, pedal position and pressure
required to maintain a desired heading varies
During flight, pedal position and pressure with main rotor torque variations, altitude and
required to maintain a desired heading varies airspeed conditions. Control linkage includes a
with main rotor torque variations, altitude and bungee spring that relieves left pedal forces in
airspeed conditions. Control linkage includes a flight.
bungee spring that relieves left pedal forces in
flight. When the helicopter is on the ground, pedal
toseat distance is adjusted by removing
When the helicopter is on the ground, pedal quickrelease pins on top of pedal arms and
toseat distance is adjusted by removing repositioning pedals.
Table 101. Troubleshooting Tail Rotor and Vibrations

Heavy mediumfrequency vibration Tail rotor out of balance. Rebalance tail rotor assembly (Ref.
in tail rotor assembly; vibration Sec. 182000).
sometimes felt in pedals as a
buzzing sensation. Runout of tail rotor transmission Replace transmission if shaft runout
output shaft excessive. exceeds 0.0025 inch (0.0635 mm)
T.I.R. No axial play allowed. (Ref.
Sec. 632510).
Page 101
640000 Revision 21
MAINTENANCE MANUAL
Table 101. Troubleshooting Tail Rotor and Vibrations

High frequency vibration, primarily Tail rotor blades slightly out of Rebalance tail rotor assembly (Ref.
in pedals as a buzzing sensation. balance. Sec. 182000).
Tail rotor blade pitch bearings Replace tail rotor pitch bearings (Ref.
worn. COM).
Excessive wear in pitch control link Replace pitch control link bearings
bearings. (Ref. COM).
NOTE: High frequency vibrations in Excessive wear of swashplate or Replace swashplate or repair pitch
the helicopter can also be large bearings in housing of pitch control assembly (Ref. COM).
caused by components of other control assembly.
systems (Ref. Sec. 182000,
534000, 632510 and Excessive play in tail rotor fork Replace fork bearings (Ref. COM).
Chap. 71). bearings.
Tail rotor hubtofork play. Repair (Ref. COM).
Excessive dents in leading edge of Replace blade(s) or tail rotor

blades. assembly. (Ref. COM).
Insufficient torque on stabilizer Retorque mount bolts (Ref. Chap.

mount bolts. 53).
Insufficient torque on tail rotor Retorque retaining nut (Ref. Sec.

assembly retaining nut. 643000).
Excessive play in pitch control link Worn pitch control link bearings. Replace pitch control link bearings
assemblies. (Ref. COM).
High left pedal forces required in Bungee spring (Sta. 63) Reconnect or replace bungee spring
flight. disconnected, broken or stretched. (Ref. Sec. 672000).
Pedals binding. Excessive drag of pitch control Clean swashplate bore and
swashplate on transmission shaft. transmission shaft splines.
Relubricate splines.
Snapping noise heard in Noise is normal action of strap None required.
nonoperating tail rotor when pitch pack and caused by laminates
angle changed from one extreme twisting and bending when blade is
to the other. feathered without centrifugal load
present.
Page 102
Revision 34 640000
MAINTENANCE MANUAL
Section
640005
FourBladed Tail
Rotor Assembly
Initial Installation
(369D/E)
MAINTENANCE MANUAL
FOURBLADED TAIL ROTOR ASSEMBLY

1. FourBladed Tail Rotor Initial Installation (5). Remove existing station 284 bellcrank
and tail rotor control rod (Ref. Sta. 284
This section contains procedures for initial Bellcrank Removal).
installation of fourbladed tail rotor kit, which
includes tail rotor; tail rotor transmission; and C. FourBladed Tail Rotor Transmission
parts for modifying overcenter trim system BuildUp
controls and engine/rotor tachometer indicator.
(Ref. Figure 901) Buildup the fourbladed tail
This kit may be installed on all Model 500D
rotor transmission as follows.
and 500E helicopters at the owners/operators
discretion.
NOTE: Components of the fourbladed tail ro- (Ref. Section 910000)
tor drive system kit are assembled and bal- Item Nomenclature
anced at the factory. Prior to installation of CM112 Antiseize compound high temperature
the kit, some existing equipment must be re-
CM305 Lacquer, acrylic
moved from the helicopter, and other equip-
ment must be modified.
Do not lift transmission assem-
A. Tail Rotor and Transmission Initial CAUTION bly by coupling flange.
Installation
(1). Install shims, coupling and coupling
Install the fourbladed tail rotor transmission bolt. Coat threads of bolt with anti
and tail rotor assembly according to the seize compound (CM112). Torque bolt to
following procedures. 250 300 inchpounds (28.25 33.90
Nm) plus drag torque.
B. Existing Tail Rotor and Transmission
Removal (2). Add stripe of white paint (CM305)
approximately 0.0125 inch (3.175 mm)
Remove the following equipment from helicop- wide between ends of decal to allow for
ter before installing fourbladed tail rotor indexing of aft end of drive shaft.
transmission and tail rotor assemblies.
NOTE: To locate new coupling index, use flash-
(1). Remove existing twobladed tail rotor light and look through control tube rod hole
(Ref. Sec. 642000). in aft tailboom fitting. Rotate output shaft
until index stripe on coupling is at six oclock
(2). Remove tail rotor transmission and position.
driveshaft (Ref. Sec. 632510).
D. Drive Shaft, Tail Rotor Transmission and
NOTE: Retain bolt for use when building up Tail Rotor Installation
fourbladed tail rotor transmission, cou- (Ref. Figure 901) Install drive shaft, transmis-
pling is a limitedlife item. If sufficient ser- sion and tail rotor on helicopter as a unit. Do
viceable life remains on coupling, it may be not install with blades mounted.
reused with fourbladed tail rotor installa-
tion. If not, discard and replace coupling
bolt. Consumable Materials
(3). Remove bolt, coupling and shims from Item Nomenclature
transmission output shaft (Ref. Sec. CM305 Lacquer, acrylic
631510).
(4). Remove index stripe on drive shaft at (1). Install existing drive shaft on tail rotor
Sta. 137.5. transmission (Ref. Sec. 631510).
Page 901
640005 Revision 21
MAINTENANCE MANUAL
TAIL ROTOR
TRANSMISSION
DAMPER
COUPLING
TAIL ROTOR
DRIVESHAFT
STA. 137.50
COUPLING
TAIL ROTOR
TRANSMISSION
(4BLADED)
WHITE STRIPES 0.125 IN.

(3.175 MM) WIDE
WHITE STRIPES 0.125 IN.

(NEW CONFIGURATION) (3.175 MM) WIDE
TAIL ROTOR
DRIVESHAFT
WHITE PAINT MARKING

AT 6 0CLOCK
DOUBLER
STATION 137.50
RING
STA. 137.50
(LOOKING FORWARD)
NOTE: ADD STRIPE OF WHITE PAINT ON COUPLING AT LOCATION

SHOWN, APPROXIMATELY 0.125 IN. (3.175 MM) WIDTH AND
LENGTH, AND AT CONTROL ROD HOLE AT AFT SIDE OF HOUSING. G640001A
Figure 901. Tail Rotor Index Stripe Requirements
Page 902
Revision 21 640005
MAINTENANCE MANUAL
(2). Install assembled unit on helicopter Install bungee installation

(Ref. Sec. 631510). WARNING tool (ST508) before discon-
necting any pilots collective stick
(3). Paint 0.125 inch (3.175 mm) wide and hardware. There is strong bungee
0.125 inch (3.175 mm) long stripe spring pressure present in stick link-
(contrasting color to aft tailboom age. If suddenly released, spring reac-
fitting) at six oclock position of control tion in linkage can cause personal inju-
rod in aft tailboom fitting to align stripe ry or parts damage.
on coupling.
(3). Remove bellcranks and collective
(4). Add white index stripe (CM305) on tail bungee spring and bracket; disconnect
rotor drive shaft to match stripe on and retract lateral cyclic trim actuator
doubler at Sta. 137.5. assembly.
(5). Install new tail rotor control rod. Turn off electrical switches
WARNING and disconnect any external
(6). Attach new Sta. 284 bellcrank to new
tail rotor pitch control assembly. power from helicopter prior to refuel-
ing or defueling. Static discharge spark
(7). Temporarily install bellcrank to new in presence of fuel vapors can cause
control rod assembly. fire or an explosion.
(8). Install blades on hubs. Install inboard (4). Drain all fuel from fuel cells; purge cells
blades first (Ref. Sec. 641000). with dry filtered compressed air.
E. Tail Rotor Control OverCenter Trim (5). Fold and displace left fuel cell to permit
System Rework bucking of rivets at aft side of canted
wall.
The tail rotor overcenter trim system must be
reworked when fourbladed tail rotor is G. FourBladed Over Center Trim System
installed. Necessary parts for this rework are Initial Installation
included with fourbladed tail rotor kit.
(Ref. Figure 902)
F. TwoBladed OverCenter Trim System
Removal
Special Tools
Prior to rework of over center trim system, (Ref. Section 910000)
following existing equipment must be removed Item Nomenclature
and preparations made.
ST508 Collective bungee installation tool
Special Tools
(Ref. Section 910000) (1). Locate and clamp fitting (1) and
Item Nomenclature serrated plate (2) together with serra-
ST508 Collective bungee installation tool tions facing away from fitting. Drill one
0.159 inch (4.0386 mm) diameter rivet
hole with a #21 bit and countersink
(1). Remove tail rotor bungee; disconnect hole.
floorrouted tail rotor control rod and
remove and discard spring fitting from (2). Locate serrated plate (3) and clamp to
rod. Remove tail rotor idler bellcrank seat support structure (4). Ensure
under pilot seat. serrations are facing away from seat
support structure. Mark rivet and
(2). Disconnect tunnelrouted tail rotor screw holes on serrated plate (3) and
control rod and lateral mixer control seat support structure. Remove ser-
rod at lower rod end. rated plate from seat support structure.
Page 903
640005 Revision 21
MAINTENANCE MANUAL
11 34
36
35
20
21
12
14 9
(NOTE 2)
13
23 15
2 (REF) 3 (REF) 21
NOTE 1
22
8
1.00 IN. (NOTE 2) 24
1.00 IN. (2.54 CM) 26 19
(2.54 CM)
25
26
0.612 IN. 0.612 IN. 32
2.50 IN.
(15.5448 MM) (15.5448 MM) (6.35 CM)
33
31
10
30 30 27
29 28
17 18
6 2
3
CL 1.75 IN.
(4.445 CM)
1.00 IN. 2.00 IN.

4 (2.54 CM) (5.08 CM)
16
3.31 IN.
(8.4074 CM) PILOTS FLOOR
(REF)
NOTES:
1. REMOVE 0.120.14 IN. (3.0483.556 MM) ON 369A7304 BRACKET.
2. NOT REQUIRED WHEN 369D27304 BRACKET IS INSTALLED. G640002A
Figure 902. Over Center Trim System Installation
Page 904
Revision 21 640005
MAINTENANCE MANUAL

1. FITTING 19. RIVET
2. SERRATED PLATE 20. BOLT
3. SERRATED PLATE 21. WASHER
4. SEAT SUPPORT STRUCTURE 22. NUT
5. RIVET 23. COTTER PIN
6. RIVET 24. BOLT
7. BRACKET 25. BUSHING
8. BRACE 26. WASHER
9. BRACKET 27. NUT
10. BELLCRANK 28. COTTER PIN
11. BOLT 29. BOLT
12. BUSHING 30. WASHER
13. WASHER 31. NUT
14. WASHER 32. COTTER PIN
15. NUT 33. TAIL ROTOR BUNGEE
16. BOLT 34. SCREW
17. WASHER 35. WASHER
18. NUT 36. NUT
NOTE: Head of rivets not to protrude past base (8). Install fitting (1) on seat support
of serrations. structure using bolts (16), washers (17)
and nuts (18).
(3). Attach fitting (1) and serrated plate (2)
together with one rivet (5). NOTE: Shim BSC bracket (9), as required, for
proper fit on canted wall. Shims are not re-
(4). Locate and drill two 0.2500.254 inch quired for 3 bracket (9).
(6.356.4516 mm) diameter screw holes (9). Locate and clamp bracket (9). Drill five
and two 0.098 inch (2.4892 mm) 0.1930.199 inch (4.90225.0546 mm)
diameter rivet holes using a #40 bit diameter holes using existing rivet
through seat support structure to pattern (Ref. Figure 903).
match previously marked locations
(step (2).). Countersink rivet holes. (10). Attach bracket (9) to canted wall using
five rivets (19) or alternate method of
(5). Drill two 0.098 inch (2.4892 mm) five screws (34), washers (35) and nuts
diameter rivet holes with a #40 bit thru (36).
serrated plate (with round bolt holes)
(11). Grasp brace (8) and hold against
using previously marked locations (step
bracket (9). Mark mating holes on brace
(2).). Attach serrated plate (3) to seat
(8) with those on bracket (9).
support structure using two rivets (6).
(12). Remove brace (8) from bellcrank (10)
NOTE: Check part number of bracket (7). If and bracket (7). Drill two 0.2500.254
bracket is a 369A7304, proceed with step inch (6.356.4516 mm) diameter holes
(6). If 369D27304 bracket is installed, brace at locations marked in step (11)..
(8) and bracket (9) are not required, proceed
to step (14). (13). Install brace (8) on bracket (9) with
bolts (20), washers (21) and nuts (22).
(6). Remove 0.120.14 inch (3.0483.556 Align opposite end of brace (8) between
mm) maximum material, as required, bracket (7) and bellcrank (10).
from bracket (7) boss lug to achieve a (14). Install bolt (11), bushing (12) and
snug fit between brace (8), bracket (7) washers (13, 14) thru bracket (7) and
and bellcrank (10). bellcrank (10). Install nut (15) and
cotter pin (23).
(7). Temporarily attach bellcrank (10),
brace (8) and bracket (7) with bolt (11), (15). Reinstall tunnelrouted control rods
bushing (12), washers (13, 14) and nut and floorrouted control rods, with
(15) finger tight. spring fitting removed.
Page 905
640005 Revision 21
MAINTENANCE MANUAL
Always use bungee installa- assembly of collective bungee. Coat

WARNING tion tool (ST508) when re- parts with grease (CM111) as in-
moving attaching hardware. Reaction structed. Ensure that 0.120 inch (3.048
of spring when pressure is suddenly re- mm) of threads are visible between nut
leased can cause personal injury or and rod end of bungee female bearing
parts damage. assembly.
NOTE: Adjust tail rotor pedal force by tighten- Remove bungee installation
ing or loosening the 0.120 inch (3.048 mm) WARNING tool only as instructed.
thread adjustment on bungee female bear- There is strong bungee spring pressure
ing assembly. Tighten to maximum 0.120 present with fourbladed tail rotor
inch (3.048 mm) thread adjustment on bun- bungee installed. If suddenly released,
gee female bearing assembly increases ped- spring could cause personal injury
al force approximately five pounds; loosen- and/or parts damage.
ing decreases pedal force. Bungee spring
may be attached to any of four holes in fit- (2). Attach assembled bungee to fitting (1)
ting (1). If excessive left pedal force is re- using attaching hardware (29 thru 32)
quired, position spring at lower hole. and to bellcrank (10) using attaching
hardware (24 thru 28). Ensure bushing
H. FourBladed Tail Rotor Controls Rigging (25) extends 0.0100.080 inch
(0.2542.032 mm) beyond surface of
bungee rod end.
(Ref. Section 910000) I. Horizontal Stabilizer Tip Weight Removal
Item Nomenclature
Tip weights installed in horizontal stabilizer
CM111 Grease, aircraft for twobladed tail rotor operation are not
used with fourbladed tail rotor system.
Special Tools Remove and discard four screws securing tip
(Ref. Section 910000) plates and weights to horizontal stabilizer.
Item Nomenclature Reinstall tip plates using four new screws (P/N
ST508 Collective bungee installation tool NAS140315).
ST510 Bungee spring compression tool rod and J. N2 and NR (Rotor) Tachometer Indicator
channel Replacement
ST606 T/R swashplate rigging tool
Remove and replace existing tach indicator
with indicator supplied in fourbladed tail
Rigging of fourbladed tail rotor controls is to rotor kit (Ref. Sec. 953000).
be done with tail rotor bungee spring removed.
Tail rotor pitch angles at 3/4 radius shall be: K. FourBladed Tail Rotor System
Completion of Installation
Full right pedal 14 1 Upon completion of kit installation, the
following actions must be completed.
Full left pedal 31 +10
Neutral pedal 7.5 1 (1). Replace all components, access panels,
covers, etc. removed to gain access to
Rig tail rotor controls per Tail Rotor Controls work area.
Rigging except use fourbladed tail rotor (2). Check installation of fourbladed tail
control rigging tool (ST606). After rigging, rotor control linkage for discrepancies.
reinstall tail rotor bungee and carefully
remove bungee installation tool (ST508) using (3). Fill tail rotor transmission with oil (Ref.
bungee compression tool rod and channel Sec. 120000).
(ST510).
(4). Refuel helicopter and perform opera-
(1). Assemble bungee using bungee installa- tional check of fourbladed tail rotor
tion tool (ST508) and instructions for control system (Ref. PFM).
Page 906
Revision 21 640005
MAINTENANCE MANUAL
(5). Ensure that Pilot Flight Manual L. Weight and Balance

Supplement is inserted in Section IX,
Rotorcraft Flight Manual.
Weight and balance changes resulting from
(6). Ensure that installation of fourbladed installation of fourbladed tail rotor kit are
tail rotor kit and appropriate part listed in Table 901. After kit installation,
numbers, serial numbers and limited incorporate changes in helicopter weight and
life data are recorded in helicopter log balance record as instructed (Ref. Sec.
book. 081000).

Pounds (kg) inches (cm) inlb (kg cm)
Added +9.4 (+4.2638) 257.2 (653.228) +2417.68 (27854.574)

Removed 0.0 0.0 0.0
Net Change +9.4 (+4.2638) 257.2 (653.228) +2417.68 (27854.574)
Page 907
640005 Revision 21
MAINTENANCE MANUAL
BL 0.00
BRACKET
BRACE
OK TO LEAVE
RIVET (5 REQD) EXISTING RIVETS.
(USE EXISTING (NOTE)
RIVET PATTERN)
WL 13.10
0.032 IN.
BRACKET (0.8128 MM)
STATION 78.50
CANTED WALL BL 0.00 BL 6.00 L.H.
NOTE:
BL 0.00 OMIT THESE TWO RIVETS WHEN
INSTALLING 369D270035 ONLY.
BRACKET
BRACE
OK TO LEAVE
RIVET (4 REQD) EXISTING RIVET
(USE EXISTING
RIVET PATTERN) SHIM AS REQUIRED BETWEEN
BULKHEAD AND BRACKET
WL 13.10
BRACKET
0.032 IN.
SHIM AS REQUIRED BETWEEN (0.8128 MM)
BULKHEAD AND BRACKET
BL 6.00 L.H.
BL 0.00
STATION 78.50
CANTED WALL
BSC
G640003A
Figure 903. Bracket Installation Sta. 78.50 Canted Wall
Page 908
Revision 21 640005
MAINTENANCE MANUAL
Section
641000
Tail Rotor Blades
(369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR BLADES

1. Tail Rotor Blades Scratches that do not exceed 0.020 inch
(0.508 mm) depth are permissible if
Blades are cambered for high thrust to provide repaired.
directional control at high altitude. Each
consists of an aluminum honeycomb spar, (4). Loose or missing tip weights and
aluminum skin, riveted aluminum blade attachment hardware.
fittings and an aluminum tip cap; all structur- (5). Clogged drain openings.
ally bonded together.
(6). Adhesive separation at exposed edges.
At manufacture, static balancing moments of
all blades are within plus or minus 40 gram (7). Debonding of tip cap from tail rotor
inches of each other by use of a special blade (Ref. Tail Rotor Blade Tip Cap
balancing fixture and prebalancing with tip Repair).
weights. Although erosion or allowable repairs (8). Tip cap rivets for installation and
may cause minor balance moment changes, condition (Ref. Tail Rotor Blade Tip Cap
such changes are considered negligible enough Repair).
to allow direct replacement of any used blade
with a new one and interchangeable use of (9). Tail rotor blade pitch bearings for a
blades with remaining service life. In any case maximum 0.250 inch (6.350 mm) play
of blade selection or use, inspection, repair and measured at tip of blade.
serviceability requirements must be complied 3. Abrasion Strip Dye Penetrant and Tap
with. Retirement schedule and remaining Test Inspection
service life of a used blade should always be
considered when making decision to replace a (Ref. Figure 202)
single blade (Ref. Sec. 040000).
2. Tail Rotor Blade Inspection (Ref. Section 910000)
Item Nomenclature
(Ref. Figure 201) Perform balance check at
intervals specified (Ref. Sec. 052000). If any CM729 Tape, masking, pressure sensitive
of following conditions exist, perform appropri- CM801 Abrasive paper, silicon carbide
ate detailed inspections and allowable repairs
(Ref. COM). (1). Using a 1/8 inch (3.175 mm) drill bit
(1). Surface cracks, scratches, nicks, and a pencil, fabricate a tapping
gouges, dents, pits or corrosion. hammer by taping drill bit to pencil.
Drill bit should be a minimum of six
(2). Leading edge erosion or dents. Visually inches (15.24 cm) from end of pencil
check abrasion strip for paint cracking that is to be held while tapping.
or chipping along abrasion strip/airfoil NOTE: Voids are indicated by a dull, dead tone.
bond line. Use 10X glass to check Slight tone changes will occur near the tip
abrasion strip/airfoil bond line for cap and along the length of the strip. These
debonding between epoxy adhesive and should not be mistaken for voids.
abrasion strip. If debonding has
occurred, remove blade from service. (2). Using the fabricated tapping hammer,
tap test the entire abrasion strip. Hold
NOTE: If abrasion strip debonding is sus- end of pencil opposite drill bit and tap
pected, but cannot be confirmed by visual with shank (rounded) end of drill bit. If
inspection, (Ref. Abrasion Strip Dye Pene- void indications are noted, remove
trant and Tap Test Inspection). blade from service.
(3). Root fitting cracks, scratches, nicks and (3). Mask area of blade around abrasion
gouges. No cracks are allowable. strip with masking tape (CM729).
Page 201
641000 Revision 34
MAINTENANCE MANUAL
DRAIN OPENING
BALANCE WEIGHT
BLADE
TIP CAP
CLEAR LACQUER
ROOT FITTING DRAIN OPENING
HUB
RED
TRUNNION
CLEAR LACQUER
ORING
WHITE NUT
CRUSH WASHER
BUSHING
BUSHING
CRUSH WASHER BOLT
3.0 IN. (7.62 CM) RED
3.0 IN. (7.62 CM) WHITE
BLADE
3.0 IN. (7.62 CM) RED
G641000A
Figure 201. Tail Rotor Blade
Page 202
Revision 21 641000
MAINTENANCE MANUAL
SHOWN ABOVE: UNBONDING OF EPOXY ADHESIVE AND ABRASION STRIP

WITH SEPARATION BETWEEN ABRASION STRIP AND
AIRFOIL SURFACE, BLADE UNACCEPTABLE FOR SERVICE.
SHOWN RIGHT: UNBONDED AND DISPLACED ABRASION STRIP AT

BLADE TIP; SEPARATION BETWEEN ABRASION
STRIP/AIRFOIL SURFACE ALONG BOND LINE,
BLADE UNACCEPTABLE FOR SERVICE.
DRILL BIT, 1/8 IN.

PENCIL (3.175 MM)
TAPE
MIN. 6.0 IN.
(15.24 CM)
TAPPING TOOL FOR FABRICATION
G641002A
Figure 202. Inspection of Tail Rotor Blade Abrasion Strip
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641000 Revision 21
MAINTENANCE MANUAL
Do not use chemical paint re- ure. Bond failure is indicated by penetrant
CAUTION mover to remove paint from bleedout from under the abrasion strip, and
abrasion strip. Chemicals can attack the will appear as a line along the edge of the
abrasion strip to blade bonding agent. strip. The 5X magnifying glass will aid dis-
tinguishing between porosity voids and
(4). Using 220 grit abrasive paper (CM801), bleedout from under the abrasion strip. It
sand dry, removing all paint from the may be necessary to wipe off, then reapply
abrasion strip. Ensure abrasion to the developer to distinguish between poros-
airfoil bondline is exposed. Clean paint ity voids and bond separations. The most
dust from blade. positive indication of bond failure will nor-
mally appear during the first one to seven
NOTE: Do not remove masking tape from blade minutes following developer application.
until completion of dye penetrant inspec-
tion. (8). Using a 5X magnifying glass, examine
bond line to determine if penetrant dye
(5). Visually check abrasion strip to blade is indicating a bond separation. If bond
bonding using a 10X magnifying glass. separation is noted, remove blade from
If bond failure is obvious, remove blade service.
from service.
(9). Remove masking tape from blade.
(6). Dye penetrant inspect, according to
manufacturers instructions. (10). Inspect blade for cleanliness and paint
damage. Clean and repair paint
(a). Inspect entire abrasion strip to blade damage as necessary (Ref. Sec. 2030).
bond line, including abrasion strip
bond in blade tip cap area. NOTE: Do not repaint abrasion strip or abra-
sion strip to blade bond line.
(b). Apply penetrant using a small brush
or swab to prevent damage to blade (11). Check tail rotor balance (Ref. Sec.
paint, and to minimize cleanup. 182000).
(c). Allow penetrant to remain on surface (12). If blade is removed from service
of abrasion strip bondline for five because of separation or voids, notify an
minutes minimum. Approved MDHS Service Center or
Distributor for disposition. Those
(d). Use dry lint free cloth or paper towel blades in which voids are found shall be
to remove excess penetrant. sent to an approved repair station for
abrasion strip replacement.
(e). Apply remover to cloth or lint free
towel to remove remaining surface 4. Tail Rotor Blade Tip Cap Repair
penetrant.
(Ref. Figure 203)
NOTE: Never spray or flush area of inspection
with cleaner.
(f). Ensure thorough penetrant removal (Ref. Section 910000)
from surface before applying develop- Item Nomenclature
er. CM222 1,1,1Trichloroethane
(7). Apply a light film of developer on the CM318 Primer
area of examination. CM411 Adhesive, epoxy
NOTE: The epoxy adhesive used to bond abra-
sion strip to blade may have porosity voids.
The penetrant will form a circular pattern (1). Remove tail rotor blade from helicopter
around voids resulting from porosity. These (Ref. Tail Rotor Blade Replacement
circular patterns do not indicate bond fail- Procedure).
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MAINTENANCE MANUAL
0.60 IN. (1.524 MM)

0.250 IN. (6.35 MM) (NOTE 1)
DIA HOLE
0.30 IN. (0.762 MM)
AFTER REMOVAL OF DEBRIS, SEAL 0.250 IN.

(6.35 MM) DIA. HOLE WITH 2 PLIES OF 120 0.390 0.060 IN.
FIBERGLASS CLOTH & 3135 A & B EPOXY (9.91 1.524 MM)
RESIN (CREST PRODUCTS OR EQUIVALENT)
AS SHOWN. HOLE LOCATION
SURFACE PREPARATION: ABRADE SURFACE
WITH EMERY CLOTH AND WIPE WITH 1, 1,
1TRICHLOROETHANE SOLVENT. DO NOT
ALLOW RESIN TO BUILD UP IN 0.250 IN. (6.35
MM) DIA. HOLE.
0.690 IN. (17.53 MM)

ALONG BLADE CONTOUR
NOTE 2
0.380 IN.
0.250 IN. (9.65 MM)
(6.35 MM)
0.30 IN. 0.250 IN.

(7.62 MM) (6.35 MM)
NOTE 2
0.50 IN. (12.70 MM)

ALONG BLADE CONTOUR
(NOTE 2)
NAS 1739B42 RIVET
(4 PLACES)
NOTES:
1. FIBERGLASS THIS AREA. DO NOT PLACE FIBERGLASS
CLOTH OVER OPENING FOR BALANCE WEIGHTS.
2. USE NO.27 DRILL AND 1005 COUNTERSINK WITH NO. 30
PILOT. COUNTERSINK TO MAXIMUM 0.035 IN. (0.889 MM) DEPTH.
INSTALL NAS 1739B42 RIVET. SEAL RIVET WITH CLEAR
EPOXY (CM411). G641001A
Figure 203. Installation of Tip CapToTail Rotor Blade Rivets
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641000 Revision 21
MAINTENANCE MANUAL
Handle blade carefully. Dents, 5. Tail Rotor Blade Replacement Procedure

CAUTION nicks or scratches may cause
balance problems at reinstallation, or make Consumable Materials
blade unserviceable. (Ref. Section 910000)
Item Nomenclature
(2). With blade on a clean hard surface,
CM318 Primer
measure and mark locations for rivet
holes.
NOTE: Always record number and location of
(3). Using No. 27 drill, carefully drill holes existing balance washers when replacing
at locations marked on outboard and blade. This record aids in dynamic balance
inboard surfaces of blade. troubleshooting.
(4). Using 100 1 countersink with No. 30 (1). Remove cotter pin, nut, washer and
pilot, countersink holes to 0.035 inch pitch arm bolt from outboard end of
(0.889 mm) maximum depth. pitch control link.
Bolt, nut, washers and bushings
(5). Apply primer (CM318) to holes and CAUTION may be reinstalled if service-
install rivets while primer is wet. able. If bushing and crush washers are to be
reused, they must be installed in the exact
(6). Coat installed rivets with clear epoxy location from which they were removed. If
(CM411). either the blade or strap pack assembly from
which they were removed is replaced, re-
(7). Drill a 0.250 inch (6.35 mm) diameter place crush washers and bushing. Bushings
hole through tip cap (Ref. Figure 203). must be free of nicks and burrs.
Tip cap is 0.070 inch (1.778 mm) thick
at point to be drilled. NOTE: If same blade is to be reinstalled, retain
intact for reuse. Note and record number
(8). Remove FOD from blade interior and type of balance washers and attach-
through hole. ment hardware used on bolt at blade pitch
arm.
Trichloroethane may damage (2). Remove bolt that secures blade to
CAUTION blade paint finish. outboard strap pack shoes.
(9). Abrade surface surrounding hole using (3). Withdraw blade from hub trunnion.
emery cloth (CM804); wipe clean using Do not disassemble strap shoes
clean cloth dampened with trichloroe- CAUTION from end of strap pack protrud-
thane (CM222). ing from trunnion. Strap pack parts are not
individually replaceable and must remain
Do not allow resin to buildup in
CAUTION hole.
assembled. Avoid damaging strap pack.
Scratches or nicks on strap pack laminates
may make strap pack unserviceable.
(10). Bond two plies of 120 fiberglass cloth
over hole with 3135A and B epoxy resin NOTE: No axial play is allowed in the strap as-
or equivalent. Allow epoxy to cure sembly shoes. Rotational movement is per-
according to manufacturers instruc- missible.
tions.
(4). If strap pack is to remain exposed for
any length of time, wrap exposed end of
(11). Reinstall tail rotor blade on helicopter strap pack with wax paper or other
(Ref. Tail Rotor Blade Replacement similar nonabrasive material to
Procedure). protect from damage.
(12). Check and adjust tail rotor blade (5). If blade being removed is to be rein-
balance (Ref. Sec. 182000). stalled, do not remove blade tip screw,
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Revision 21 641000
MAINTENANCE MANUAL
any balance washers or weight from (13). Install pitch control links (Ref. Sec.
blade. 643000).
NOTE: Remove old primer from mating sur- NOTE: If same blade that was removed is being
faces and attaching hardware prior to reas- reinstalled, install same number of balance
sembly. washers on pitch arm bolt that were present
prior to removal of blade. For different
(6). To install blade, remove any protective
blade, install balance washers required for
covering from strap pack extending
static chordwise balance of assembled tail
from hub trunnion.
rotor which have been determined with a
(7). Install Oring and slide blade on hub balance fixture.
with blade leading edge facing in
counterclockwise direction. Use care to (14). Balance tail rotor (Ref. Sec. 182000).
keep blade correctly aligned so that hub
trunnion slides into blade pitch bear- 6. Tail Rotor Abrasion Strip Riveting
ings. Do not use force.
(8). Align bolt holes in root fitting with hole adding rivets at the outboard ends of the
through bushing in outboard shoes of abrasion strip to provide a secondary failsafe
strap pack. method of attachment.
(9). Coat contacting surfaces of bushings, This procedure is effective on tail rotor blades:
washers, nuts and bolts with unthinned 369A16137, 503, 505,
primer (CM318) and immediately 369D21606BSC,
perform following steps. 369D2161311, 31, 41, 51,
369D21615BSC, 21,
(10). Assemble and install bolt, bushings and 421088
washers in sequence (Ref. Figure 201).
Make certain that direction of bolt is
opposite to that of opposing blade. Do Consumable Materials
not force bolt; it must have an easy but (Ref. Section 910000)
snug fit through blade, shoes and Item Nomenclature
bushings. CM222 1,1,1Trichloroethane
NOTE: It is recommended that the MS 21250 CM318 Primer
bolt be replaced with any of the alternate CM804 Emery cloth, fine
bolts with the higher torque at the operators N/A Fiberglass cloth, No. 120
earliest convenience.
N/A Epoxy resin, Spec. 3135A and B or any 2
(11). If an MS 21250 bolt is installed, install part (1:1) clear epoxy resin
nut and torque to 600 650 inch
pounds (67.79 73.44 Nm) while
Do not attempt to perform this
primer is wet. If an HS54826, CAUTION procedure with the tail rotor
HS44416, or an LWB226 bolt is
installed, torque nut to 750 775 blades installed on the helicopter. Failure to
inchpounds (84.74 87.56 Nm). comply with this caution may result in de-
fective rivet installation and possible blade
After blade is secured to strap damage.
CAUTION pack assembly, do not allow
blade pitch travel from neutral to exceed 30 (1). Remove tail rotor blades from helicop-
degrees in either direction. Rotating blade ter (Ref. Tail Rotor Blade Replacement
to excessive pitch angles may result in unde- Procedure).
tected damage to strap assembly.
(2). Using a 10X magnifying glass, perform
(12). Check that bolthead is flat against a visual inspection of the tail rotor
bushing. No gap is permitted. If gap is blade abrasion strip bond lines for
found, replace bolt and bushing. debonding.
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MAINTENANCE MANUAL
0.60 IN. (1.524 MM)

(NOTE 1)
0.250 IN. (6.35 MM)
0.30 IN. (7.62 MM)
HOLE
CL
NOTE 2
0.810 0.030 IN.
0.390 0.060 IN. (20.57 0.762 MM)
(9.91 1.524 MM)
HOLE LOCATION
1.160 0.030 IN.

(29.464 0.762 MM)
0.280 0.030 IN. (7.110 0.762 MM)

ALONG CONTOUR (BOTH SIDES)
ABRASION STRIP
BLADE SKIN
VIEW LOOKING
DOWN
NOTE:
1. FIBERGLASS THIS AREA. DO NOT PLACE FIBERGLASS CLOTH OVER OPENING
FOR BALANCE WEIGHTS.
2. COUNTERSINK HOLE 100, DEPTH 0.0090.011 IN. (0.2290.2794 MM). G641005A
Figure 204. Tail Rotor Blade Abrasion Strip Riveting
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MAINTENANCE MANUAL
(3). If abrasion strip debonding is suspected (e). Inspect hole in abrasion strip.
but cannot be confirmed by visual
inspection, perform Abrasion Strip Dye (11). Remove FOD from interior of blade as
Penetrant and Tap Test Inspection. follows:
NOTE: Tail rotor blades removed for voids (a). Drill 0.250 inch (6.35 mm) hole
must be removed in ship sets. through tip cap as shown.
(b). Remove FOD from blade interior
(4). If voids are found in blade, remove and
through hole (there is space at tip cap
send to an authorized repair station for
end for debris to pass aft of spar).
repair.
(c). Install new rivet.
(5). Carefully secure tail rotor blade in a
suitable holding fixture. (d). Abrade surface surrounding tip cap
hole using emery cloth (CM804); wipe
NOTE: When performing the following step, clean using clean, lintfree cloth
use drill bit stop to prevent drilling through dampened with 1,1,1trichloroethane
both sides of blade. (CM222).
(6). Using a No. 27 cobalt drill bit, drill Do not allow resin to build up in
holes at locations shown (light center CAUTION hole.
punch prior to drilling is allowed).
(e). Bond two plies of fiberglass cloth over
(7). Deburr holes with a 100 countersink to hole with epoxy resin.
a depth of not more than 0.011 inch
(0.2794 mm). (12). Repeat inspection of abrasion strip.
(8). Apply primer (CM318) to holes and (13). Reinstall tail rotor blades.
install CS254541 or CR355541
(14). Perform tail rotor balance (Ref. Sec.
rivets while primer is wet.
182000, Tail Rotor Blade Balancing).
Installed rivet stems may be de-
CAUTION burred using a file. Do not re- 7. Tail Rotor Blade Abrasion Strip
move material from locking collar. Modification
(9). Inspect installed rivets.
application of a 0.0027 inch (0.06858 mm).
(10). If rivet installation is not satisfactory, thick strip of stainless steel tape over the
remove as follows: inboard end of the abrasion strip.
During removal of defective riv- This procedure is effective on tail rotor blades:
CAUTION et, observe the following: 369A16137, 503, 505, 509,
Do not damage or enlarge hole. 369D21606BSC, 509,
Do not drive or force rivet stem from hole. 369D2161311, 31, 41, 51, 71,
Do not remove rivets common to tip cap. 369D21615BSC, 21, 41,
421088
(a). Carefully grind off locking collar and
upper portion of rivet head. Consumable Materials
(b). Carefully push center stem through
Item Nomenclature
rivet sleeve.
(c). Using a drill stop, drill through rivet CM801 Abrasive paper, silicon carbide
sleeve using care to prevent hole
enlargement.
NOTE: Abrasion strip must have rivets
(d). Push remaining rivet sleeve through installed before applying stainless steel
hole. tape.
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MAINTENANCE MANUAL
(1). Using a 10X magnifying glass, perform 8. Tail Rotor Blade Protective Tape
a visual inspection of the tail rotor Installation
blade abrasion strip bond lines for
debonding. Consumable Materials
(2). If abrasion strip debonding is suspected (Ref. Section 910000)
but cannot be confirmed by visual Item Nomenclature
inspection, remove blades and perform CM220 Naphtha aliphatic
Abrasion Strip Dye Penetrant and Tap CM304 Enamel, epoxy
Test Inspection. CM801 Abrasive paper, silicon carbide
N/A 3M aerosol primer MITO0081
NOTE: Tail rotor blades removed for voids
must be removed in ship sets. N/A 3M mylar tape P/N Y86711
(3). If voids are found in blade, remove and

send to an authorized repair station for
NOTE: This installation is only approved on
tail rotor blades equipped with the new
repair.
abrasion strips.
(4). Lightly abrade faying surface of tail In an effort to reduce the amount of erosion in
rotor blade in area where tape is to be the area inboard of the abrasion strip, MDHS
installed with 400grit abrasive paper has approved the installation of mylar tape to
(CM801). the blade leading edge. Installation of the tape
is optional.
(5). Wipe abraded area with naphtha
(CM220) to eliminate grease and dirt The length of the tape can vary, up to 2.0
film. inches in length, but must be equal on both
blades.
NOTE: Do not allow temperature to exceed
120F (49C). It is recommended to start with 1.5 inch (3.81
cm) length and increase the length as erosion
(6). Using a heat gun, or equivalent, heat occurs by replacing the tape.
abraded area.
Do not cut or trim tape after
(7). Remove backing and apply stainless CAUTION installation on blade, damage to
steel tape to leading edge of tail rotor blade will occur.
blade.
(1). Measure length of eroded area on blade
(a). Apply tape so it overlaps each side of with the most erosion.
blade equally.
NOTE: Tape must be of equal length on both
(b). Tape should overlap the inboard end blades to ensure proper balance.
of abrasion strip 0.50 0.03 inch (2). Cut tape long enough to cover erosion
(12.70 0.762 mm) at the leading plus approximately 0.50 inch (12.70
edge of blade. mm) overlap on leading edge abrasion
strip.
NOTE: Abrasion tape must be free of surface
wrinkles or air bubbles. (3). Round off square corners of tape to
reduce peeling.
(8). Smooth and press tape into place by
hand. (4). Lightly abrade faying surface of tail
rotor blade in area where tape is to be
(9). Reapply pressure by hand following installed with 400 grit abrasive paper
initial installation to ensure proper (CM801).
bonding.
(5). Wipe abraded area with naphtha
(10). Perform tail rotor balance (Ref. Sec. (CM220) to eliminate grease and dirt
182000, Tail Rotor Blade Balancing). film.
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Revision 21 641000
MAINTENANCE MANUAL
1.00 IN.
(2.54 CM)
3.00 IN.
(7.62 CM)
0.50 IN.
(12.70 MM)
1.00 IN.
(2.54 CM)
OLD STYLE ABRASION STRIP

NOTES 1 AND 2
0.50 IN.
(12.70 MM)
0.50 IN.
(12.70 MM)
NEW ABRASION STRIP
NOTES:
1. 304 STAINLESS STEEL OR MYLAR TAPE SHALL BE APPLIED; 0.50 IN. (12.70 MM)
TO ABRASION STRIP AND 0.50 IN. (12.70 MM) TO TAIL ROTOR BLADE.
2. APPLY TAPE EQUALLY TO BOTH SIDES OF BLADE. G641006C
Figure 205. Tail Rotor Blade Abrasion Strip Modification
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641000 Revision 22
MAINTENANCE MANUAL
(6). Treat any bare metal with epoxytype (2). If cracks are suspected, perform a dye
paint (CM304). penetrant inspection of the suspect area
as follows:
NOTE: Do not allow temperature to exceed
120F. (a). Lightly abrade faying surface of tail
rotor blade in area where tape is to
(7). Using a heat gun, or equivalent, heat be installed with 400grit abrasive
abraded area. paper (CM801).
(8). Apply aerosol primer to bonding area (b). Wipe abraded area with naphtha
and allow to dry. (CM220) to eliminate grease and dirt
film.
(9). Remove backing and apply tape to
(c). Perform dye penetrant inspection on
leading edge of blade.
the suspected area per MILI25135,
(a). Apply tape so it overlaps each side of or equivalent.
blade equally. (d). Tail rotor blades with evidence of
cracking must be removed from
(b). Tape should overlap the inboard end
service.
of abrasion strip 0.50 0.03 inch
(12.70 0.762 mm) at the leading NOTE: Tail rotor blades with the new abrasion
edge of blade. strip configuration cannot be intermixed
with tail rotor blades that have the old abra-
NOTE: Tape must be free of surface wrinkles or sion strip configuration.
air bubbles.
(e). If there is no evidence of cracking,
(10). Smooth and press tape into place by the blade can be cleaned and touch
hand. up epoxy paint applied to the affected
area.
(11). Reapply pressure by hand following
initial installation to ensure proper (3). To reduce erosion, apply protective tape
bonding. to the blades (Ref. Tail Rotor Blade
Protective Tape Installation).
182000).
182000, Tail Rotor Blade Balancing).
9. Tail Rotor Blade Leading Edge Crack B. Tail Rotor Blades with OldStyle
Inspection Abrasion Strips
(Ref. Figure 206) (1). Remove stainless steel tape from the
leading edge at the inboard end of the
abrasion strip.
(Ref. Section 910000) (2). Inspect that area for evidence of cracks;
Item Nomenclature no cracks are allowed.
CM220 Naphtha aliphatic (3). If cracks are suspected, perform a dye
CM801 Abrasive paper, silicon carbide penetrant inspection of the suspect area
as follows:
(a). By lightly abrading the blade skin,
Do not use any chemicals to re-
CAUTION move the paint and do not pene-
carefully remove the paint from the
suspected area.
trate the metal skin of the blade.
(b). Perform dye penetrant inspection on
A. Tail Rotor Blades with NewStyle the suspected area per MILI25135,
Abrasion Strips or equivalent.
(1). Inspect leading edge for any evidence of (c). Tail rotor blades with evidence of
cracking in the area shown; no cracks cracking must be removed from
are allowed. service.
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Revision 22 641000
MAINTENANCE MANUAL
NOTE: Tail rotor blades with the new abrasion (c). Using a heat gun, or equivalent, heat
strip configuration cannot be intermixed abraded area.
with tail rotor blades that have the old abra-
sion strip configuration. (d). Remove backing and apply stainless
steel tape to leading edge of tail rotor
(d). If there is no evidence of cracking, blade.
the blade can be cleaned and touch 1). Apply tape so it overlaps each side
up epoxy paint applied to the affected of blade equally.
area.
2). Tape should overlap the inboard
(4). Install new 0.0027 inch (0.06858 mm) end of abrasion strip 0.50 0.03
thick stainless steel tape in the same inch (12.70 0.762 mm) at the
location as follows (Ref. Figure 205): leading edge of blade.
(a). Lightly abrade faying surface of tail NOTE: Abrasion tape must be free of surface
rotor blade in area where tape is to wrinkles or air bubbles.
be installed with 400grit abrasive
(e). Smooth and press tape into place by
paper (CM801).
hand.
(b). Wipe abraded area with naphtha (f). Reapply pressure by hand following
(CM220) to eliminate grease and dirt initial installation to ensure proper
film. bonding.
NOTE: Do not allow temperature to exceed (5). Perform tail rotor balance (Ref. Sec.
120F (49C). 182000, Tail Rotor Blade Balancing).
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641000 Revision 22
MAINTENANCE MANUAL
PAY PARTICULAR
ATTENTION TO THIS
AREA FOR CRACKING
OLD STYLE ABRASION STRIP
PAY PARTICULAR
ATTENTION TO THIS
AREA FOR CRACKING
NEW STYLE ABRASION STRIP
88754
Figure 206. Tail Rotor Blade Leading Edge Crack Inspection
Page 214
Revision 22 641000
MAINTENANCE MANUAL
Section
642000
Tail Rotor Hub and
Fork (369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR HUB AND FORK

1. Tail Rotor Hub and Fork one inch in either direction. Unrestricted
rotation of blades on hub can excessively
(Ref. Figure 201) This section covers mainte- bend or stretch strap pack and cause un-
nance of the hub, strap pack and fork as an detected damage to strap pack and an
assembled unit. For all other maintenance outofbalance tail rotor when reas-
instructions pertaining to hub and fork sembled.
assembly, and the hub assembly, strap pack
D To prevent balance problems at reassemb-
and fork assemblies as separatelymaintain-
ly of parts and hardware, mark exact
able components, Ref. COM.
number, locations and positions of all
items before removal for correct reinstal-
When blades are removed from
CAUTION hub, exposed ends of strap pack
lation.
should be protected with covering (Ref. Sec. D On twobladed tail rotor system do not
641000). Hub and fork should be handled remove hubtodrive fork hinge bolt to
carefully to avoid damage to strap pack. remove tail rotor assembly. On four
bladed tail rotor system hubtodrive
2. Tail Rotor Hub and Fork Replacement fork hinge bolt removal is required. This
bolt should only be removed according to
A. Tail Rotor Hub and Fork Removal instructions Ref. COM. Damage to strap
pack may occur if any other procedure is
(Ref. Figure 202 and Figure 203) used.
(2). Disconnect pitch control links from

Special Tools blade pitch control arms.
Item Nomenclature (3). Pull rotating boot out of groove in fork.
(4). On fourbladed tail rotor system
remove inboard and outboard blades
On fourbladed tail rotor and hubs to access fork tang washer
WARNING system, there is strong and nut.
spring pressure in installed tail rotor
linkage. Disconnect the inline bungee NOTE: Helicopters Serial Nos. D0003 thru
before beginning disassembly. Failure D1024 had a twopiece retaining nut and
to disconnect the bungee can result in stop support. Helicopters subsequent to
personal injury and/or parts damage. D1024 have a onepiece retaining nut and
stop support.
(1). On fourbladed tail rotor, disconnect
inline bungee (Ref. Sec. 672010) if (5). Straighten tang of tang washer.
tail rotor is installed on helicopter.
(6). Using torque wrench adapter (ST607),
CAUTION loosen retaining nut and slide tail rotor
outward on output shaft of tail rotor
D Whenever blades and hub are removed as transmission to remove blade stop and
an assembly, or whenever pitch control stop support.
links are disconnected, do not allow blade
pitch to exceed 30 degrees from neutral (7). Remove nut, tang washer, tapered ring,
pitch position. This is equal to blade pitch and splitring halves that fit into recess
control arm movement of approximately at inboard end of fork.
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642000 Revision 21
MAINTENANCE MANUAL
OUTBOARD
STRAP SHOES
FORK
HUB
STRAP PACK
ASSEMBLY
INBOARD STRAP
SHOES
30 30
HUB TRUNNION (SEE CAUTION)
PITCH CONTROL LINK
DRAIN
OPENING
BALANCE
WEIGHT
TIP CAP
DRAIN
OPENING
CHORDLINE AT
NEUTRAL PITCH
CAUTION: LOOKING AT BLADE

SHOES NOT TO BE REMOVED FROM STRAP PACK, AVOID DAMAGING END (TIP)
STRAP PACK; SCRATCHES OR NICKS ON STRAP LAMINATES MAY MAKE
STRAP PACK UNSERVICEABLE. G642000
Figure 201. Tail Rotor Hub and Strap Pack
Page 202
Revision 21 642000
MAINTENANCE MANUAL
Tail rotor tang washer must not It is possible for pitch control
CAUTION be reused. CAUTION swashplate to be misaligned by
onehalf spline in relation to drive fork.
NOTE: Placing grease pencil mark on drive Make sure drive fork, pitch links and swash-
fork to key it to transmission output shaft plate are in exact alignment with transmis-
enables subsequent installation of tail rotor sion shaft centerline. If incorrectly as-
assembly at same position. sembled, swashplate will be misaligned
approximately 10 degrees from drive fork.
Application of small painted matchmark To correct this condition, remove tail rotor
next to centerline splined groove on both assembly (leaving pitch control assembly in-
pitch control assembly and tail rotor drive stalled), rotate tail rotor assembly 180 de-
fork aids reassembly at same position on grees and reinstall it.
transmission shaft. (3). Slide tail rotor assembly onto shaft
with drive forktohub pivot bolt
One spline groove of fork is located directly aligned with swashplate lugs. Position
on centerline passing through centers of the tail rotor assembly on shaft so that
two fork bearings while, at opposite side of approximately two threads at shaft end
spline bore, same centerline passes through are exposed outboard of drive fork.
a spline tooth. A similar condition exists
with respect to swashplate splines, except (4). Coat tapered ring with primer (CM318)
that reference centerline originates between and install it on shaft, making certain
swashplate arms. that tapered edge parallels chamfer in
fork. Perform the following steps while
For illustrations showing matchmarks and primer is wet.
additional information, Ref. COM. NOTE: Preassembly of tang washer, nut, stop
support and stop as a unit aids in their in-
(8). Slide tail rotor assembly off output stallation when performing steps (5). thru
shaft. (7). below. Marking outer tang that is next to
inner key on tang washer, before assembly
B. Tail Rotor Hub and Fork Installation of parts, simplifies alignment with keyway
on shaft. Teeter blades to start tang washer
(Ref. Figure 202 and Figure 203) on shaft.
(5). Slip new tang washer over exposed
Consumable Materials threads of shaft; key tang must face
(Ref. Section 910000) inboard toward gearbox. Install nut
Item Nomenclature approximately two full turns on shaft
CM115 Grease, oscillating bearing threads to verify threads engaged.
CM318 Primer (6). Slide tail rotor assembly outboard
CM702 Lockwire CRES against nut. Install stop support by
inserting it in drive shaft end.
Special Tools In next step do not force stop
CAUTION into position with screwdriver;
Item Nomenclature this can crack the stop.
ST607 Adapter, torque wrench (7). Coat contacting surfaces of stop with
grease (CM115) and insert it in stop
support.
(1). Attach rotating boot; attach to pitch
(8). Install split ring halves in shaft groove
control assembly using safety wire
and slide fork inboard until ring halves
(CM702).
are secured by recess in fork.
(2). Install split ring on output shaft of (9). Visually align a tang on tang washer
transmission. with any convenient reference point.
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642000 Revision 21
MAINTENANCE MANUAL
PITCH CONTROL ASSEMBLY
NOTE 1
SPLIT RING
(WIRE SPRING)
ROTATING BOOT TAIL ROTOR

ASSEMBLY
TRANSMISSION FORK
OUTPUT SHAFT HINGE BOLT
FORK BEARING
TANG WASHER
(NOTE 2)
RETAINING NUT
STOP SUPPORT
TAPERED RING
PITCH ARM STOP
NOTE 3
TORQUE WRENCH
AND ADAPTER
NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH
CENTERLINE TOOTHSPACE MARK ON FORK WHEN ASSEMBLED ON
OUTPUT SHAFT.
2. DISCARD USED TANG WASHER; BEND TWO TANGS TO SECURE NUT.
3. TOOL PN 369D29823 (ST607). G642001D
Figure 202. Hub and Fork Assembly Installation (TwoBladed)
Page 204
Revision 28 642000
MAINTENANCE MANUAL
NOTE 1
PITCH CONTROL
ROTATING BOOT
SPLIT RINGS PITCH ARM
FORK
TAIL ROTOR ASSEMBLY
NOTE 3
RING, FORK SUPPORT
NUT, STOP SUPPORT
TANK WASHER
(NOTE 2)
INBOARD BLADE
STOP TORQUE WRENCH AND
ADAPTER
NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH
CENTERLINE TOOTHSPACE MARK ON FORK WHEN ASSEMBLED ON
OUTPUT SHAFT.
2. DISCARD USED TANG WASHER; BEND TWO TANGS TO SECURE NUT.
3. TOOL PN 369D29826 (ST607). G642002C
Figure 203. Hub and Fork Assembly Installation (FourBladed)
Page 205
642000 Revision 21
MAINTENANCE MANUAL
(10). Torque retaining nut, using torque 3. Tail Rotor Hub and Fork Inspection
wrench adapter (ST607), to:
(Ref. Figure 201) Hub inspection is accom-
(a). Torque twobladed retaining nut to plished with tail rotor blades removed.
450 500 inchpounds (50.84 (1). Inspect areas on hub trunnions that
56.49 Nm). mate with blade pitch bearings for
excessive wear and for damage.
(b). Torque fourbladed retaining nut to
550 600 inchpounds (62.14 (2). Check hub and fork for axial play or
67.79 Nm) and ensure wirespring bearing roughness when hub is pivoted
split ring halves are firmly imbedded from one extreme to the other.
in fork recess.
(3). Check torque of fork hinge bolt. Apply
NOTE: Tang washer movement of more than 125 inchpounds (14.12 Nm) torque
one tang width is an indication that tang to nut or bolt. If bolt or nut does not
washer inner key tang is sheared. This con- rotate, preload is correct. If bolt or nut
dition requires replacement of tang washer rotates, retorque. (For repair limit,
and reassembly of parts according to initial torquing requirements and replacement
installation procedure. criteria, Ref. COM.)
(11). Check that tang has not moved more (4). Check visible areas of strap pack for
than one tang width in relation to nicks or scratches on strap laminates,
reference point noted in step (9).. cracked or kinked laminates and sharp
bends or permanent twists in lami-
NOTE: When clearance is less than 0.005 inch nates. Any one of these defects, except
(0.127 mm) or clearance does not exist, re- minor outer surface defects that can be
place tapered ring and/or fork assembly. removed by abrasive polishing, requires
replacement of strap pack. (For infor-
(12). Bend two tangs on tang washer to lock mation on allowable repairs, service-
retaining nut. When bending tangs, do ability requirements and replacement,
not forceform tang to match nut Ref. COM.)
contour; maintain natural bend radius
4. Conical Bearing Inspection
that develops at tang root.
Visually inspect conical bearings installed in
(13). Apply torque stripe paint across nut, fork assembly, at intervals specified (Ref. Sec.
tang washer and fork assembly in 052000).
location that can be checked visually.
(1). Play is not permitted in conical drive
(14). Insert edge of rotating boot into groove fork bearings.
of drive fork.
5. Elastomeric Fork Bearing Inspection
(15). Install pitch control links (Ref. Sec.
643000). Visually inspect elastomeric bearings installed
in fork assembly, at intervals specified (Ref.
(16). Position tail rotor pedals in neutral Sec. 052000) for damage and debonding
position and recheck that drive fork, from fork as follows.
pitch links and swashplate are in exact Elastomeric materials can be
alignment with transmission shaft CAUTION damaged by solvents, grease or
centerline. oil. If cleaning is necessary, refer to Elasto-
meric Bearing Care and Cleaning.
(17). On fourbladed tail rotor system,
reconnect bungee (Ref. Sec. 672010). (1). Apply teetering force by hand to rotor
blades (stoptostop). Check for
(18). Check rigging of tail rotor controls (Ref. forktobearing bond failure. Failure is
Sec. 672010). indicated by any motion between outer
Page 206
Revision 21 642000
MAINTENANCE MANUAL
bearing cage and fork (bearing turns in pounds (6.67222.24 N). If load is not
fork). If failure is noted, remove bearing within specified limit, replace bearing.
and rebond in fork according to instruc-
tions in the COM. (8). Reinstall rubber blade stop.
(2). Teeter blades stoptostop. Observe

four radial molded ridges on each
bearing as teetering takes place. If
ridges assume continuous curved
shape, bearings are intact. Discontinu-
ity in molded ridges indicates bearing
TAIL ROTOR
failure and bearing must be replaced.
(3). Check bearing for general condition.
Replace bearing if damaged. Evidence
of light swelling, pock marks and SPRING SCALE
crumbs are surface conditions and are STRING
2.00 IN.
not indications of bearing failure. (5.08 CM)
(4). Elastomeric bearings are suspected of

369F/FF
being unserviceable if visual inspection 1.00 IN.
(2.54 CM)
reveals rubber deterioration or separa-
tion, or a vibration is reported. Perform
369D/E
following steps to check blade flapping
STRING
resistance measurement to determine if SPRING SCALE
suspected elastomeric bearing has 3.00 IN. 3.00 IN.
failed. (7.62 CM) (7.62 CM)
ZERO LOAD POSITION
(5). To perform measurement, remove VIEW LOOKING AFT
G642003A
rubber blade stop between tail rotor
hub and fork on inboard hub. The Figure 204. Blade Flapping Resistance
outboard tail rotor assembly can be Check
checked without any disassembly.
6. Elastomeric Bearing Care and Cleaning
Do not remove hubtodrive
CAUTION fork hinge bolt to remove Elastomeric bearings are not inherently
2bladed tail rotor assembly. This bolt resistant to grease, oils or solvents if im-
should only be removed according to in- mersed. They are, however, somewhat resis-
structions in the COM. Damage to strap tant to occasional splash or spoilage of these
pack may occur if any other procedure is materials if exposed on an occasional basis. If
used. elastomeric materials do come in contact with
these fluids, the elastomer surface should be
(6). The rubber blade stop must be re- immediately cleaned. If cleaning is accom-
moved. Reassemble tail rotor with plished properly, the effect of greases, oils or
rubber blade stop removed. solvents on the performance of the elastomeric
material will be minimal. If replacement of
(7). Measure flapping resistance of blades elastomeric bearing is required, refer to COM.
using spring scale attached within 1.00
inch (2.54 cm) for 369D/E or 2.00 inch (1). If greases, oils or solvents come in
(5.08 cm) for 369FF inboard of blade tip contact with the elastomeric material,
(Ref. Figure 204). Block or hold tail wipe immediately with clean, dry rag.
rotor pedal in neutral position. While (2). If wiping is not sufficient (oil or grease
pulling 90 degrees from plane of is too thick), clean the affected area of
rotation, record spring scale value when the elastomer with a soft bristle brush
blade tip is 3.00 inches (7.62 cm) and a solution of pure soap and water.
inboard and outboard from noload
position. Scale must indicate 1.55.0 (3). Rinse with tap water.

642000 Revision 21
MAINTENANCE MANUAL
Section
642530
AntiTorque Fan
(500/600N)
MAINTENANCE MANUAL
ANTITORQUE FAN
1. AntiTorque Fan Assembly (8). Remove fan from helicopter.
The purpose of the fan is to provide antitor- B. AntiTorque Fan Installation

que control using a variable flow of air, across
variable pitch blades, down the tailboom. The Consumable Materials
antitorque fan liner, felt metal seal, provides (Ref. Section 910000)
a controlled gap between the fan and the felt Item Nomenclature
metal seal for optimum efficiency of the fan
during flight. CM702 Lockwire CRES
NOTE: The NOTARr antitorque control sys-

tem must be rerigged immediately after re- (1). Align and install fan assembly on
placement of any component, control rods, support shaft.
or linkages, and if helicopter operation re- (2). Install washer on shaft.
veals a rigging deficiency.
(3). Install locknut and torque nut to 40
2. AntiTorque Fan Replacement 42 footpounds (54 57 Nm). Install
lock washer.
(4). Install pitch bearing housing using six
bolts and washers, Torque bolts to 80
Special Tools 100 inchpounds (9.04 11.30 Nm)
(Ref. Section 910000) and lockwire (CM702).
Item Nomenclature
ST605 Fan nut socket (5). Install fan pitch control tube (Ref. Sec.
672030, Fan Pitch Control Tube
Installation).
A. AntiTorque Fan Removal
(6). Install tailboom (Ref. Sec. 534030).
(1). Remove tailboom (Ref. Sec. 534030).
3. AntiTorque Fan Blade Replacement
(2). Remove nut and lock washer from aft
tube assembly. (Ref. Figure 401)
(3). Remove fan pitch control tube (Ref. Sec. NOTE: When a blade needs replacement for
672030, Fan Pitch Control Tube any reason, whether it be service related or
Removal). at overhaul, replace associated bolt, washer,
and nut.
(4). Remove six bolts, washers and pitch
A. AntiTorque Fan Blade Removal
control housing from fan.
(1). Remove antitorque fan from helicopter
(5). Remove lock washer from nut and shaft (Ref. AntiTorque Fan Removal).
by releasing the holding tangs from lock
nut and pull locking ring from support (2). Remove fan blade from strap assembly
shaft knurl. by removing cotter pin, washer and pin.
(6). Remove locknut in a counterclockwise B. AntiTorque Fan Blade Installation
direction, using coupling socket (ST605)
and coupling holding fixture tool. (1). Install fan blade and align retention
hole with upper strap assembly reten-
(7). Remove washer from shaft. tion hole.
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642530 Revision 41
MAINTENANCE MANUAL
EXAMPLE OF INK MARK DATE.
MDHC P/N 500N53115

11/04
BLADE
ASSY
OO7
XX/XX
STRAP ASSY
EXPIRATION DATE
SHELTON CT.USA
S/N LK1014
(NOTE 1)
WASHER
STUD VIEW LOOKING

FORWARD
COLLAR NUT
HUB BLADE
BUSHING
BOLT
PIN
WASHER
WASHER (COUNTERSUNK)
COTTER PIN (NOTE 2)
PITCH HORN
WASHER
PITCH PLATE
NUT
FAN HUB
RETENTION PLATES
NOTE:
1. INSTALL STRAP WITH SERIAL NUMBER FACING AFT DIRECTION.
2. INSTALL WASHER WITH COUNTERSINK AGAINST BOLTHEAD. G642005C
Figure 401. AntiTorque Fan
Page 402
Revision 42 642530
MAINTENANCE MANUAL
(2). Install pin, washer and cotter pin. NOTE: Inspect strap assembly for condition
and expiration date. Pay particular atten-
(3). Reinstall antitorque fan in helicopter tion to area around the two spools. Inspect
(Ref. AntiTorque Fan Installation). for cracks in the polyurethane coating. If
any cuts or breaks are found that exceed
(4). Perform fan balance check (Ref. Sec. 0.020 inch (0.508 mm) in depth or 0.25 inch
182030, Fan Balance Check). (6.35 mm) in length, replace the strap.
D Tensiontorsion straps have a life limit
Consumable Materials that starts when their package is opened.
(Ref. Section 910000) If the date the package was opened is un-
Item Nomenclature known, the 5 year calendar life is based
on the manufacturing cure date.
CM312 Ink stamp, permanent
D Tensiontorsion straps can be put back in
their package, and life limit not started, if
not out of the package more than five
4. Fan Blade Strap and Pitch Horn days.
Replacement
(2). If tensiontorsion strap is removed
(Ref. Figure 401) Remove and install the pitch from package for no more than five
horn and strap assembly using the following days, do the steps that follow:
procedures. (a). Replace desiccant in package, use
desiccant (CM826).
NOTE: NOTE: If you can not seal package; put, ten-
D The following procedure covers the indi- siontorsion strap, package, and desiccant
vidual removal of one strap assembly and (CM826) in new plastic bag.
pitch horn. If disassembly of all is re- (b). Put tensiontorsion strap in package
quired, use the following steps for each and seal package opening with tape.
one requiring removal. (c). Put package in box and seal box with
tape.
D When strap is replaced, replace related
bolt, washer, and nut. (3). If replacement strap is new, remove
from package and write the words
A. Fan Blade Strap and Pitch Horn EXPIRATION DATE on the strap face
Disassembly and date five years after the package is
(1). Remove antitorque fan from helicopter opened. Use permanent ink (CM312).
(Ref. AntiTorque Fan Removal). (4). Make an item component record card
for each tensiontorsion strap.
(2). Remove fan blade(s) (Ref. AntiTorque NOTE: Install tensiontorsion straps so that
Fan Blade Replacement). the cure date is in view when fan is as-
(3). Remove bolt and washer retaining sembled.
bottom half of strap assembly between (5). Insert strap assembly thru top of fan
two retention plates. hub and pitch horn until lower (smaller
(4). Remove strap assembly thru top hole of diameter) hole is aligned between holes
fan hub. of two retention plates.
(6). Install blade and align spar before
(5). Remove pitch horn from fan hub. torquing inboard nut, this ensures
B. Fan Blade Strap and Pitch Horn proper alignment of strap with blade.
Reassembly (7). Install new bolt, washers (countersunk
washer against bolthead), and nut
NOTE: Counterweights on pitch arms are set thru holes of retention plates and of
by the factory; do not attempt to adjust. strap assembly.
(1). Install pitch horn in fan assembly. (8). Install fan blade(s) and torque bolts to
Ensure ball on lower side of pitch horn 100 inchpounds (11.30 Nm) (Ref.
is inserted in bushing of pitch plate. AntiTorque Fan Blade Installation).
Page 403
642530 Revision 42
MAINTENANCE MANUAL
(9). Reinstall antitorque fan in helicopter A. Support Shaft Disassembly

(Ref. AntiTorque Fan Replacement).
(1). Remove antitorque fan from helicopter
(10). Perform fan balance (Ref. Sec. (Ref. AntiTorque Fan Removal).
182030, Fan Balance Check).
(2). Remove fan pitch control tube (Ref. Sec.
5. Retention Plate and Pitch Plate 672030).
Replacement (3). Remove fan interconnect driveshaft
(Ref. Sec. 631530).
(Ref. Figure 401) Remove and install the
retention strap and pitch plate using the (4). Remove fan interconnect shaft coupling
following procedures. from support shaft (Ref. Sec. 631530).
A. Retention Plate and Pitch Plate (5). Remove support shaft and fan hub
Disassembly housing from fan support assembly by
removing four cotter pins, nuts,
(1). Remove antitorque fan from helicopter washers and bolts.
(Ref. AntiTorque Fan Removal).
(6). Remove hub spacer from shaft.
(2). Remove fan blades (Ref. AntiTorque
Fan Blade Replacement). (7). Remove bearing retainer from support
housing.
(3). Remove strap assemblies and pitch
horns. (8). Press shaft and fan support bearing out
of support housing.
(4). Remove pitch plate and retention plates
from fan hub. NOTE: Removal of bearing seal at disassembly
is not required unless seals need replace-
B. Retention Plate and Pitch Plate ment.
Reassembly (9). Remove bearing seal from support
(1). Position retention plates in fan hub. housing and bearing retainer.
(10). Press bearing off support shaft using
NOTE: Install tensiontorsion straps so that
removal ring.
the cure date is in view when fan is as-
sembled. B. Support Shaft Reassembly
(2). Install pitch horn and strap assemblies
(Ref. Strap and Pitch Horn Reassemb- Consumable Materials
ly). (Ref. Section 910000)
Item Nomenclature
(3). Place pitch plate over retention plates CM111 Grease, aircraft
within fan hub.
(4). Install fan blades (Ref. AntiTorque
Fan Blade Installation). (1). Install removal ring on support shaft
(5). Reinstall antitorque fan in helicopter until firmly seated against shoulder of
(Ref. AntiTorque Fan Installation). support shaft.
(2). Install support bearing on support
6. Support Shaft Replacement shaft.
(Ref. Figure 402) Remove and install the (3). Install bearing seal in support housing
support shaft using the following procedures. and bearing retainer using sealant
(CM425).
NOTE: When replacing pitch plate and/or sup-
port shaft bearings, do not use 900R bear- (4). Fill seal cavity with 3.34.0 CCs of
ings in the 500/600N helicopters. grease (CM111).
Page 404
Revision 41 642530
MAINTENANCE MANUAL
(5). Install support bearing and shaft in (2). Removal with Hand Tool:
support housing.
(a). Insert the applicable size hex wrench
(6). Install bearing retainer and align bolt into the pin wrenching cavity and
holes on support housing. hold securely to prevent pin rotation.
(b). Rotate the collar counterclockwise
(7). Install hub spacer on shaft. with pliers or vise grips to remove.
(8). Install support shaft and housing on (c). Tap out pin with a nonmetallicfaced
fan support assembly. using four bolts, mallet.
washers, and nuts. Torque nuts to 40
50 inchpounds (4.52 5.65 Nm). B. Fan Balance Stud Installation
Install cotter keys. Pins may be reused, provided the finish has
not been marred and the threads and wrench-
(9). Install fan interconnect shaft coupling ing cavity are in acceptable condition.
on support shaft (Ref. Sec. 631530).
(10). Install fan interconnect driveshaft (Ref. Consumable Materials
Sec. 631530). (Ref. Section 910000)
Item Nomenclature
(11). Install fan pitch control tube (Ref. Sec. CM409 Adhesive, epoxy
672030).
(12). Install antitorque fan on helicopter (1). Apply adhesive (CM409) to pin and
(Ref. AntiTorque Fan Installation). insert, while wet, using a nonmetallic
faced mallet or rivet set into hole.
(13). Check fan balance (Ref Sec. 180030, Ensure Pin is seated flush against fan
Fan Balance Check). hub.
7. Fan Balance Stud Replacement (2). Manually screw the collar onto the pin
a minimum of two threads.
A. Fan Balance Stud Removal
(3). Installation with Pneumatic Tool:
The following procedure is for removal of the (a). Insert the hex wrench tip of the
balance studs when the lock collars have power driver into the wrenching
become loose and allow the stud to rotate. cavity in the pin
(1). Removal with Pneumatic Tool: Pneu- (b). Press the power driver socket firmly
matic tools may be used only on against the collar and actuate the
fasteners in interference fit holes and driver until the collar wrenching
fasteners with aluminum collars. device is torqued off.
(a). Select the applicable removal tool. Fit (c). Withdraw the hex wrench tip from
removal tool to a 0.375 inch (9.525 the wrenching cavity and discard the
mm) square socket drive that will fit wrenching collar.
a reversible screwdriver motor. (4). Installation with hand tool:
(b). Place the collar removal tool over the (a). Press socket from hand tool firmly
collar and press firmly. onto collar.
(c). Rotate the tool counterclockwise by (b). Insert hex wrench though center of
hand until the teeth bite into the tool and hold pin to prevent it from
collar. rotating.
(d). Place the motor on the drive socket (c). Turn socket clockwise, while holding
and unscrew the collar using reverse hex wrench, until collar is firmly
drive. seated against fan hub; wrenching
collar will torque off when proper
(e). Tap out the pin with a nonmetallic torque is reached. Discard wrenching
faced mallet. collar.
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642530 Revision 41
MAINTENANCE MANUAL
AFT CONTROL TUBE

(REF)
SUPPORT SHAFT
COTTER KEY
WASHER
NUT
FAN SUPPORT ASSEMBLY

FAN SUPPORT (REF)
BEARING
BEARING
HOUSING
BEARING
RETAINER
RING
WASHER
BEARING
BOLT SEAL
FAN
(REF)
WASHER
BEARING LOCKWASHER
SEAL
HUB
SPACER
LOCKNUT
PITCH WASHER
SLIDER
BOLT
INNER BEARING
RETAINER
PITCH BEARING LOCKWASHER PITCH BEARING

PLATE HOUSING
PITCH BEARING NUT

RETAINER
WASHER BOLT
G642006A
Figure 402. AntiTorque Fan Support Shaft
Page 406
Revision 41 642530
MAINTENANCE MANUAL
8. Pitch Horn Counterweight Set Screw NOTE: Ensure counterweighttopitch horn

Replacement index mark aligns correctly. All counter-
weights are indexed the same.
(Ref. Figure 403) If, during fan inspection, a (7). Align index mark on counterweight to
counterweight is found to be loose, the set match with mark on pitch horn and
screw must be replaced. install into pitch horn.
(8). Apply grade B locking compound
Consumable Materials (CM321) to threads of set screw and
(Ref. Section 910000) install into pitch horn. Tighten set
Item Nomenclature screw.
CM216 Loctite remover
CM321 Surface primer locking compound COUNTERWEIGHT
INDEX MARK
COUNTERWEIGHT
(1). Apply heat to loose counterweight.
(2). Remove and discard set screw.
(3). Remove retaining ring and washer.
(4). Inspect threads in counterweight for

condition and cleanliness. PITCH HORN
INDEX MARKS
SET SCREW
(5). Clean pitch horn threads with Loctite PITCH HORN
remover (CM216).
G642011
(6). Apply grade T primer (CM321) to
threads of new set screw; allow to dry Figure 403. Pitch Horn Counterweight Set
for 30 minutes at ambient temperature. Screw Replacement
Page 407
642530 Revision 41
MAINTENANCE MANUAL
Page 408
Revision 34 642530
MAINTENANCE MANUAL
ANTITORQUE FAN
INSPECTION/CHECK
1. AntiTorque Fan Inspection (c). Scoring; axial marks from bearing
installation or removal.
Inspect the antitorque fan for the following
conditions: (d). Damaged spines; none allowed.
(1). All components for cracks, nicks, (e). Corrosion and pitting.
corrosion or excessive wear.
(2). Fan support bearing for free movement
(2). Tensiontorsion straps for nicks or cuts of set.
in polyurethane coating. No exposed (3). Fan support bearing retainer and
kevlar fibers allowed. Spools for cracks. housing for:
(3). Hubtoblade bushings for cracks. (a). Cracks; none allowed.
(4). Pitch horn for excessive wear (outof (b). Wear.
round condition).
(c). Scoring; axial marks from bearing
(5). Counterweights on pitch horn for installation or removal.
security. If loose, perform Pitch Horn
Counterweight Set Screw Replacement. (4). Bearing seals for condition.
NOTE: Access the forward counterweights (5). Hub spacer for cracks and wear.
through the fan inlet. Fan hub fairing must
3. AntiTorque Fan Liner (Felt Metal Seal)
be removed for access (Ref. Sec. 533030).
Inspection
(6). Pitch plate bushing for excessive wear, (1). Inspect for cracks and debonding of
grooves or cracking. liner material.
(7). Blades for cracks, nicks or impact (2). Inspect for cracks around the radius
damage. cutouts of fan support.
(8). Inspect gap between fan blade and tip (3). If cracks are found, stop drill and
seal. Inspect gap between fan blade and inspect every 50 hours (Ref. Sec.
hub (inboard end of the blade). If gap 052020).
for any blade end exceeds the average
gap of the other blades by more than NOTE: Cracks protruding into the Felt Metal
0.10 inch (2.54 mm), remove and Seal are unacceptable, replace seal (Ref.
inspect the tensiontorsion strap for AntiTorque Fan Liner (Felt Metal Seal)
that blade. Replacement).
2. Support Shaft Inspection (4). Inspect aft Pseal for tears, deteriora-
tion and debonding.
Inspect the support shaft and its associated
components as follows: 4. Fan Blade Inspection (100Hour)
NOTE: Ensure proper pitch plate and/or sup- Consumable Materials

port shaft bearings are installed. 900R bear- (Ref. Section 910000)
ings are not to be used in the 500/600N heli- Item Nomenclature
copters.
(1). Support shaft for:
(a). Cracks; none allowed. (1). Inspect polypropylene portion of fan
blade for nicks, scratches, abrasions
(b). Wear. and bulges; pay particular attention to
Page 601
642530 Revision 42
MAINTENANCE MANUAL
leading edge and area around the pin outboard end of blade are reason for
near the outboard edge of blade. blade rejection.
(3). Seal cracks up to 0.10 inch (2.54 mm),
(a). Nicks and abrasion pits that are less coming from area of pin with sealing
than 0.040 inch (1.016 mm) deep and compound (CM437).
0.25 inch (6.35 mm) in diameter may
be blended out. (No more than two (4). If any cracks larger than 0.10 inch (2.54
such repairs can be made per blade.) mm) are found, replace blade.
5. Fan Pitch Slider Inspection
(b). Nicks, scratches and abrasion pits
less than 0.020 inch (0.508 mm) and (1). Inspect slider for dents, scratches,
1.5 inch (3.81 cm) long may be nicks, gouges and corrosion, none
blended out. (Total length of all allowed.
repairs not to exceed 2.0 inch (5.08
cm).) (2). Inspect Karon coating on slider for
condition.
(2). Any bulges or blisters over 0.10 inch (3). Measure across slider, minimum
(2.54 mm) long in area of pin near diameter is 0.805 in. (20.447 mm).
Page 602
Revision 39 642530
MAINTENANCE MANUAL
ANTITORQUE FAN
REPAIRS
1. AntiTorque Fan Liner (Felt Metal Seal) NOTE: On installation of liner assembly, peel
Replacement shim laminates equally among the four
shims to provide a tight fit without deform-
(Ref. Figure 801) ing the liner at screw holes and aircraft
structure.
A. AntiTorque Fan Liner (Felt Metal Seal)
Removal (2). Install four screws. Torque screws per
standard aircraft practices.
(1). Remove tailboom (Ref Sec. 534030).
Do not install sealant in butt
CAUTION splices of liner until after felt-
(2). Disconnect safety wire and remove nut,
lockwasher, 3 bolts, washers and pitch metal is turned/cut to correct clearance. Do-
bearing retainer plate. ing so will damage cutting tool and cause in-
correct cutting radius to liner seal.
(3). Remove pitch bearing and inner pitch
bearing retainer; remove pitch slider (3). Install sealant (CM425) in mating bores
from pitch bearing housing (Ref. Sec. (cutouts) and around liner edges.
672030). (4). After installing the fan liner and before
installing the fan, trim liner felt metal
(4). Remove fan assembly (Ref. AntiTorque seal (Ref. AntiTorque Fan Liner (Felt
Fan Replacement). Metal Seal) Machining). Refer to MD
Helicopter Field Service Representative
(5). Remove sealant around liner edges
for additional information.
with plastic scraper.
C. AntiTorque Fan Liner (Felt Metal Seal)
(6). Remove four screws that secure the Machining
liner to the aircraft structure.
NOTE: Mark liner to aircraft structure to en-
sure proper clocking upon installation. If
Special Tools
liner is not installed in same position, felt
metal seal machining will be necessary for
Item Nomenclature
correct fan clearance.
ST603 Tip seal cutter
(7). Carefully slide liner aft through
support structure and fan support NOTE:
struts.
D Do this procedure only after a new fan lin-
B. AntiTorque Fan Liner (Felt Metal Seal) er is installed.
Installation D Felt metal material can cause FOD con-
tamination.
Consumable Materials (1). Apply masking tape and plastic sheet to
(Ref. Section 910000) fan duct and fan diffuser areas.
Item Nomenclature
Use only cutter and equipment
CM425 Sealing compound CAUTION supplied with (ST603) tip seal
tool.
(1). Install fan liner so that the larger NOTE: Make sure (ST603) tip seal tool is clean
cutouts fit around the fan support before you install it.
struts and the smaller cutouts fit
around the rivets that secure the fan (2). Install pin (5) and spacer (6) in fan
inlet fairing. support assembly.
Page 801
642530 Revision 42
MAINTENANCE MANUAL
FELT METAL SEAL

FELT METAL SEAL
BEFORE TRIM
AFTER TRIM

PSEAL
SCREW
LINER
PSEAL SHIM
FAN
G642007
Figure 801. AntiTorque Fan Liner (Felt Metal Seal)
Page 802
Revision 21 642530
MAINTENANCE MANUAL
10 FAN SUPPORT ASSEMBLY (REF)

7 21 (4 PL)
8
20 (4 PL) 20 (4 PL)
19 (4 PL)
11 9
15 (REF) 1 (REF)
16 (REF)
6
18
CUTTING
CL 5 DIRECTION
2
CUTTER
7 12

4
22

15
13 (2 PL)

14 (2 PL)

16
23 (2 PL)
17

CALIBRATION OF CUTTING TOOL HEIGHT G642008A
1. FAN TIP SEAL TOOL (PART 1) 13. CAP SCREW

2. CALIBRATION ARM 14. WASHER
3. CUTTER 15. POSITION LOCK KNOB
4. MOTOR COLLET 16. ADJUSTMENT KNOB
5. PIN 17. SPEED HANDLE
6. SPACER 18. AIR PRESSURE VALVE
7. THRUST BEARING 19. BOLT
8. SPACER 20. WASHER
9. NYLON WASHER 21. NUT
10. THRUST BEARING RETAINER 22. BALL LOCK PIN
11. THREADED KNOB 23. SPACER
12. FAN TIP SEAL TOOL (PART 2)
Figure 802. AntiTorque Fan Liner Felt Metal Seal Machining
Page 803
642530 Revision 42
MAINTENANCE MANUAL
(3). Install bolts (19), washers (20), and Eye protection, a respirator,
nuts (21). Torque nuts. WARNING gloves, and protective cloth-
ing must be worn during fan liner ma-
(4). Put cutter (3) in motor collet (4). Do not chining.
tighten collet.
(22). Loosen position lock knob (15) and turn
(5). Apply a thin film of oil to inner side of adjustment knob (16) to position cutter
pin (5) and outer side of tool (1) shaft. (3) for a cut of not more than one fourth
width of cutter (3). Tighten lock knob.
(6). Put thrust bearing (7) on tool (1) shaft.
(23). Connect speed handle (17) to tool (12).
(7). Put tool (1) in pin (5) and push forward.
(24). Connect pneumatic pressure source to
(8). Turn tool (1) by hand and adjust cutter tool (12).
(3) to highest point on fan liner. Tighten
collet (4). (25). Turn valve (18) to adjust cutter (3)
speed.
(9). Remove tool (1).
(26). Turn speed handle (17) and turn tool (1)
(10). Remove thrust bearing (7) from tool (1) counterclockwise at a moderate to
shaft. slow rate. Do not force cut.
(11). Put calibration arm (2) on tool (1). (27). After one full turn, again loosen
position lock knob (15) and turn
(12). Measure dimension between cutter (3) adjustment knob (16) to position cutter
and stop on calibration arm (2). (3) for a cut of not more than one fourth
width of cutter (3). Tighten lock knob.
(13). Loosen motor collet (4) and move cutter
(3) out 0.0400.050 in. (1.021.27 mm) (28). Do step (27). again and again until fan
or until cutter touches stop on calibra- liner is fully machined.
tion arm (2). Tighten collet.
(29). Disconnect pneumatic pressure source
(14). Loosen position lock knob (15) and turn to tool (12).
adjustment knob (16) until cutter (3) is
at aft most position. Tighten position (30). Disconnect speed handle (17) from tool
lock knob. (12).
(31). Remove cap screws (13), washers (14),
(15). Put thrust bearing (7) on tool (1) shaft.
and spacers (23).
(16). Put tool (1) in pin (5) and push forward. (32). Remove ball lock pin (22) and tool (12).
(17). Install spacer (8), thrust bearing (7), (33). Remove threaded knob (11), nylon
thrust bearing retainer (10), nylon washer (9), thrust bearing retainer (10),
washer (9), and threaded knob (11). thrust bearing (7), and spacer (8).
Tighten knob.
(34). Remove tool (1).
(18). Put tool (12) on tool (1) and install ball
lock pin (22). (35). Remove thrust bearing (7) from tool (1)
shaft.
(19). Install cap screws (13), washers (14),
and spacers (23). Torque cap screws. NOTE: The following clearance may vary be-
cause of variations in blade length.
(20). Make sure there is no radial or axial
movement in tool (1). (36). Install fan assembly and check for a
0.10 in. (2.54 mm) maximum clearance
(21). Lubricate tool motor, use pneumatic between fan blade ends and felt metal
tool oil. seal.
Page 804
Revision 42 642530
MAINTENANCE MANUAL
(37). In step (13). did cutter touch stop on NOTE: The antitorque control system must be
calibration arm? rerigged immediately after removal or re-
placement of control rods, linkages and com-
ponents or if helicopter operation reveals a
(a). No, go to step (11).
rigging deficiency.
(b). Yes, go to step (38). (41). Install fan assembly (Ref. AntiTorque
Fan Replacement).
(38). Remove nuts (21), washers (20), and (42). Install interconnect driveshaft (Ref.
bolts (19). Sec. 631530).
(43). Install fan pitch control rod (Ref. Sec.
(39). Remove pin (5) and spacer (6) from fan 672030).
support assembly.
(44). Install pitch slider and inner pitch
bearing retainer (Ref. Sec. 672030).
(40). Clean fan duct and diffuser areas and
remove masking tape and plastic sheet. (45). Install tailboom (Ref. Sec. 534030).
Page 805
642530 Revision 42
MAINTENANCE MANUAL
2. AntiTorque Fan Bearing Regreasing (2). Carefully remove both seals from
bearings (seals will be reused at
reassembly).
Special Tools
(Ref. Section 910000) (3). Inspect seals for damage; no damage is
Item Nomenclature allowed.
ST614 Fan bearing regreasing tool (4). Install bearings between regreasing
tools with a 4 inch (10 cm) 1024
threaded bolt, washers and wing nut.
(Ref. Figure 803 and Figure 804) The following
procedure is for the regreasing of the NOTE: The following procedure provides 100%
500N5364 and 500N7120 bearings. grease fill. Normal grease fill is 30 to 50%.
Excess grease will extrude past seals for
several hours of operation until the proper
Consumable Materials level is met.
Item Nomenclature (5). Purge bearing with grease (CM111)
CM111 Grease, aircraft until clean grease protrudes from all
four holes in back of tool.
(6). Remove regreasing tool.
NOTE:
(7). Hand spin bearing to purge excess
D Ensure proper pitch plate and shaft sup-
grease.
port bearings are installed. 900R bear-
ings are not to be used in the 500/600N NOTE: Ensure seals are serviceable. If new
helicopters. seals are required, seals and bearings must
D Refer to Figure 804 for instructions on come from the same vendor.
the manufacture of a regreasing tool. (8). Carefully install seals.
(1). Remove bearings from fan assembly (9). Reinstall bearings (Ref. Support Shaft
(Ref. Support Shaft Disassembly). Reassembly).
BOLT
WASHER
FAN BEARING
WASHER
NUT
REGREASE TOOL
PART A
REGREASE TOOL
PART B
GREASE FITTINGS
G642010A
Figure 803. Fan Bearing Regreasing Procedure
Page 806
Revision 42 642530
MAINTENANCE MANUAL
0.50 IN.
A
0.125 IN. (3.175 MM) (12.7 MM)
0.188 IN. (4.7752 MM) (NOTE 1)
DIA THRU HOLE
3.00 IN.
0.580 IN.
(7.62 CM)
(14.732 MM)
1.980 IN.
(5.0292 CM) 1.180 IN.
(2.9972 CM)
0.870 IN.
1.640 IN. (22.098 MM)
(4.1656 CM)
2.280 IN.
(5.7912 CM)
0.094 IN. (2.3876 MM) DIA 0.040 IN.

THRU HOLE (8 PL) (1.016 MM)
A
EQUALLY SPACED AND SECTION AA
PART A
CENTERED BETWEEN GREASE FITTING
MACHINED GROOVES MS150021 (2 PL)
B 0.094 IN. (2.3876 MM) DIA THRU
HOLE (2 PL) EQUALLY SPACED 1/428 TAPER
AND CENTERED BETWEEN THREADS
MACHINED GROOVES (NOTE 2)
SEAL MATERIAL (3PL) (PARTS

A AND B) USE LOCALLY
AVAILABLE MATERIAL FIRM
HARDNESS [ 75
SECTION BB
B
PART B QUANTITY STOCK SIZE DESCRIPTION
NOTES: 1 4 x 4 x .50 PLATE

1. DIMENSION MAY VARY DEPENDING ON SEAL MATERIAL THICKNESS AVAILABLE. 1 4 x 4 x .50 PLATE
2. ALL OTHER DIMENSIONS SAME AS PART A. 1 AN2364 BOLT
MATERIALS: 2 AN960D10L WASHER
1. 6061T651 ALUMINUM PER QQA250/11 OR EQUIVALENT. 1 AN3153R NUT
2. SURFACE FINISH 125 RMS. 2 MS150021 GREASE FITTING
3. BREAK SHARP EDGES 0.0020.015 IN. (0.05080.381 MM).
1 M6855/2 RUBBER
4. CHEMICAL FILM TREAT PER MILC5541.
5. DIMENSION TOLERANCE 0.010 IN. (0.254 MM).
G642009B
6. GROOVE DIAMETERS TO BE CONCENTRIC TO 0.188 IN. 4.7752 MM) DIA WITHIN 0.002 IN. (0.0508 MM).
Figure 804. Fan Bearing Regreasing Tool (ST614)
Page 807
642530 Revision 42
MAINTENANCE MANUAL
Page 808
Revision 42 642530
MAINTENANCE MANUAL
Section
643000
Tail Rotor Pitch
Control Assembly
(369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR PITCH CONTROL ASSEMBLY

1. Tail Rotor Pitch Control Assembly On fourbladed tail rotor
WARNING system, there is strong
(Ref. Figure 203 and Figure 204) The pitch spring pressure in installed tail rotor
control assembly consists of a swashplate that
linkage. Disconnect the inline bungee
rotates in a matched set of two bearings
before beginning disassembly. Failure
swaged inside a housing. A selfaligning
bearing staked in place at the underside of the to disconnect the bungee can result in
housing provides a pivot for transferring personal injury and/or parts damage.
motion of Sta. 284 bellcrank to the housing.
Clevis ears on end of the swashplate provide
for connection of pitch control links. Movement (1). Remove tail rotor hub and fork assem-
of Sta. 284 bellcrank shifts the housing axially bly (Ref. Sec. 642000).
on the output shaft of the tail rotor transmis-
sion and moves pitch control links inward and
outward to change pitch of tail rotor blades. NOTE: The manner in which the pitch control
The swashplate is retained in the pitch control assembly is installed determines rotor
housing by a washer and locknut. blade orientation to transmission splined
shaft. Installing rotor blades at 90 degrees
2. Tail Rotor Pitch Control Assembly to high and low extremes of shaft runout,
Replacement using reference marks placed on shaft at
time of shaft inspection (Ref. Sec. 632510)
A. Tail Rotor Pitch Control Assembly
Removal reduces chance of highfrequency vibration
and lessens likelihood of having to reba-
(Ref. Figure 203 and Figure 204) lance tail rotor.
DIRECTION OF PITCH CONTROL

ASSEMBLY WOBBLE ON OUTPUT SHAFT
0.020 IN.
(0.508 MM)
MAX. BOLT HOLE
CENTERLINE PITCH CONTROL
ASSEMBLY
010 LB (050 N)
SPRING SCALE
(NOTE 1)
TWINE
WASHER
NOTES: PIVOT
1. FORCE REQUIRED TO SLIDE PITCH CONTROL PIN (NOTE 2)
ASSEMBLY INWARD OR OUTWARD ON OUTPUT
SHAFT MUST NOT EXCEED THREE POUNDS (13.4 N)
WITH PITCH LINKS, BELLCRANK AND RUBBER BOOTS PITCH
DETACHED FROM PITCH CONTROL ASSEMBLY. CONTROL LINK
2. ADD ONE OR TWO AN960KD516 WASHERS AS
REQUIRED FOR CLEARANCE AT PEDAL FULL STROKE. STA. 284
BELLCRANK
G643000A
Figure 201. Pitch Control Assembly Wobble Check
Page 201
643000 Revision 21
MAINTENANCE MANUAL
0.015 IN. (0.381 MM) install Sta. 284 bellcrank. Rotate

MIN. CLEARANCE bellcrank back and forth to align
bellcrank bearing with transmission
arm.
(5). If previously disconnected, reconnect
tail rotor bungee.
HOUSING
SWASHPLATE 3. Tail Rotor Pitch Control Link Replacement
SWASHPLATETOHOUSING Consumable Materials

CLEARANCE G643001A (Ref. Section 910000)
Figure 202. SwashplatetoPitch Control Item Nomenclature
Housing Clearance CM318 Primer
(2). Remove Sta. 284 bellcrank from

transmission (Ref. Sec. 672010) so Prior to removal of pitch control
CAUTION links, colorcode pitch arm bolt
that pivot pin in bellcrank is disen-
gaged from selfaligning pivot bearing and all washers used at each arm. The bolt,
in pitch control housing. or an identical one, and same combination of
washers must be reassembled at locations
(3). Cut lockwire and pull nonrotating boot from which removed, or tail rotor balance
from groove in pitch control housing. can be seriously affected. Do not allow blade
angles to exceed 30 degrees, approximately
(4). Slide pitch control assembly off trans- one inch (2.54 cm), in each direction. Unde-
mission output shaft. tected damage to tensiontorsion strap pack
B. Tail Rotor Pitch Control Assembly may occur.
Installation (1). Disconnect ends of pitch control link
(Ref. Figure 203 and Figure 204) from clevis ear of swashplate and from
blade pitch control arm.
Consumable Materials (2). To install, insert either end of pitch
(Ref. Section 910000) control link between clevis ears of
Item Nomenclature swashplate.
(3). Install colorcoded attaching hardware
CM702 Lockwire CRES and tighten nut to 30 40 inch
pounds (3.39 4.52 Nm); install cotter
(1). Insert edge of small end of nonrotating pin with wet primer (CM318).
boot into tail rotor transmission (4). Pull pitch control assembly inboard or
housing groove. Make certain that outboard as required to align pitch
drain holes in boot are downward. control link bearing with pitch control
(2). Align spline index marks and slide arm bushing.
pitch control assembly on shaft. (5). Place special (reduced outside diame-
(3). Insert nonrotating boot edge into ter) washer and largediameter spring
groove of pitch control housing and washer on pitch arm bolt so that
secure with lockwire (CM702). concave surface of spring washer is
against bolt head. With washers in
(4). Apply grease (CM115) to Sta. 284 place on bolt, insert bolt through
bellcrank pivot pin, insert pin into pitch bearing of pitch control link and
housing selfaligning bearing and bushing in pitch control arm.
Page 202
Revision 36 643000
MAINTENANCE MANUAL
PITCH CONTROL
LINK (2) TYPICAL
NUT PITCH ARM

BOLT (STUD) SPECIAL WASHER
SPRING (NOTE 4)
BALANCE WASHER(S) WASHER
(NOTE 3)
NOTE 1
SPLIT RING
(WIRE SPRING)
TAIL ROTOR
ASSEMBLY
PITCH CONTROL
ASSEMBLY (NOTE 5) HINGE
TRANSMISSION BOLT
OUTPUT SHAFT
ROTATING
BOOT NOTE 2
FORK
FORK BEARING
PITCH ARM
0.255 IN. (6.477 MM)

ORIGINAL THICKNESS BLADE PITCH ARM
PITCH ROOT FITTING

CONTROL
0.070 IN. (1.778 MM) MAX. WEAR LINK
ALLOWED 2 PLACES EACH END
LINK WEAR LIMIT
0.02 IN. (0.508 MM) MAX. HUB
NOTES:
0.0010.130 IN. 1. CENTERLINE TOOTHSPACE MATCHMARK
(0.0253.302 MM
LINK MUST ALIGN WITH CENTERLINE TOOTHSPACE
SWASHPLATE
BEARING MARK ON FORK WHEN ASSEMBLED ON
HUBTOBLADE PITCH
OUTPUT SHAFT.
ARMCLEARANCE
(TYPICAL 2 PLACES) 2. INSTALL WITH WET PRIMER.
LINK BEARING AXIAL PLAY
3. QUANTITY (IF ANY) DETERMINED BY BALANCE
REQUIREMENTS.
4. REDUCE OUTER DIAMETER.
5. FOR DISASSEMBLY, REFER TO CSPCOM5.
G643002C
Figure 203. Tail Rotor Pitch Control Assembly (TwoBladed)
Page 203
643000 Revision 21
MAINTENANCE MANUAL
PITCH CONTROL
LINK (2) TYP
COTTER KEY
STATIONARY BOOT (NOTE 2)
NUT
WASHER
NUT
NOTE 1
WASHER
BOLT
PITCH CONTROL
ASSEMBLY (NOTE 5)
PITCH CONTROL LINK ROTATING BOOT
SPLIT RINGS PITCH ARM

BLADE PITCH
ARM
PITCH CONTROL
LINK (2) TYPICAL
ROOT FITTING SPECIAL TAIL ROTOR

HUB WASHER ASSEMBLY
(NOTE 4)
SPRING
WASHER
PITCH ARM BOLT (STUD)

BALANCE WASHER(S) (NOTE 3) NUT
0.0010.130 IN.
(0.0253.302 MM) 0.020 IN. (0.508 MM)
MAX.
HUBTOBLADE PITCH ARM SWASHPLATE

CLEARANCE (TYP 2 PLCS)
LINK BEARING 0.255 IN. (6.477 MM)

ORIGINAL THICKNESS
LINK BEARING AXIAL PLAY
0.070 IN. (1.778 MM) MAX. WEAR

ALLOWED (2 PLCS) EACH END
LINK WEAR LIMIT

NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH CENTERLINE
TOOTHSPACE MARK ON FORK WHEN ASSEMBLED ON OUTPUT SHAFT.
2. INSTALL WITH WET PRIMER.
3. QUANTITY (IF ANY) DETERMINED BY BALANCE REQUIREMENTS.
4. REDUCE OUTER DIAMETER.
5. FOR DISASSEMBLY, REFER TO CSPCOM5. G643003C
Figure 204. Tail Rotor Pitch Control Assembly (FourBladed)
Page 204
Revision 21 643000
MAINTENANCE MANUAL
(6). Install washer and nut on end of the drag check. If drag exceeds three
bolt that extends through pitch arm. pounds (13.4 N), remove pitch control
Torque nut to 50 60 inchpounds assembly and clean swashplate and
(5.65 6.78 Nm); install cotter pin with transmission shaft splines. Use solvent
wet primer (CM318). (CM234) and grade 400 abrasive paper
(CM801) or crocus cloth (CM803). Clean
(7). Check for clearance between pitch link again with solvent (CM234) and coat
and tail rotor hub pivot bolt. output shaft splines with light film of
grease (CM115).
(8). If removed from pitch arm bolt, install
balance washer(s) of same color code as (2). Inspect fork and hub for scratches,
pitch control arm and secure with nut. nicks, dents, cracks, corrosion and
similar surface defects. Check for wear
4. Tail Rotor and Pitch Control Assembly caused by rubbing of aluminum
Repair support. Scratches and nicks that do
not exceed 0.005 inch (0.127 mm)
(Ref. Figure 203 and Figure 204) depth, 0.120 inch (3.048 mm) depth at
inside corner of fork, may be repaired
Consumable Materials (Ref. COM). Worn areas resulting from
(Ref. Section 910000) rubbing of aluminum support up to
Item Nomenclature 0.060 inch (1.524 mm) depth may be
CM801 Abrasive paper, silicon carbide repaired (Ref. COM).
(3). Check wirespring split ring halves for
Repair allowable surface defects on fork and damage.
hub that may be reworked by using grade 320
(4). If brinelling wear of inner surfaces of
abrasive paper (CM801) to round out and
swashplate clevis ears is detected, 0.003
blend defect. Apply exterior surface touchup
inch (0.076 mm) depth is allowable
treatment and paint touchup (Ref. Sec.
without rework or repair. For wear of
203000). (Repairable damage limits are
greater depth, Ref. COM, for limits and
defined in the Component Overhaul Manual.)
allowable repairs.
5. Tail Rotor Pitch Control Assembly (5). If there is evidence of swashplate
Inspection contact with housing, check that
(Ref. Figure 203 and Figure 204) minimum clearance of 0.015 inch (0.381
mm) exists through 360 degrees of
rotation with axial loading applied. If
Consumable Materials contact is apparent or if axial play can
(Ref. Section 910000) be measured, replace swashplate or
Item Nomenclature bearings (Ref. COM).
NOTE: Wobble may be accurately measured by
CM234 Solvent, drycleaning attaching dial indicator support to tail rotor
CM801 Abrasive paper, silicon carbide drive fork, with indicator probe contacting
CM803 Crocus cloth swashplate clevis ear. Use care not to allow
pitch control assembly to slide on output
shaft while measuring wobble.
(1). If tail rotor control system drag or
friction is suspected, use spring scale (6). If pitch control assembly wobbles on
(Ref. Figure 201) to measure drag transmission output shaft, up to 0.020
(sliding friction) of pitch control inch (0.508 mm) is allowable. If greater
assembly on shaft of tail rotor transmis- amount of wobble is present, replace
sion. Note that pitch control links, Sta. swashplate, pitch control housing,
284 bellcrank and rubber boots must be bearings (Ref, COM) or the complete
detached from the assembly during assembly.
Page 205
643000 Revision 40
MAINTENANCE MANUAL
(7). Check that hubtoblade pitch arm 6. Tail Rotor Blade Stop Inspection
clearance is 0.0010.130 inch
(0.0253.302 mm). NOTE: Change of blade pitch angle when tail
rotor is not rotating can produce audible
snapping noise. Noise results as lamina-
(8). Inspect all bolts and nuts for security.
tions of blade strap pack are twisted and
bent without a centrifugal load. Such noise
(9). Inspect boots for installation and is normal and does not indicate a defect.
deterioration.
(1). Teeter blades back and forth and check
(10). Perform following inspections for pitch for evidence of abnormal binding. Some
control bearings at times specified (Ref. stiffness is normal, especially when
Sec. 052000) and when bearing blade stop is newer.
condition is questionable.
(2). Inspect blade stop for deterioration. Be
sure to check for cracking or splitting in
(a). Remove cotter pin, nut, washers and stem area of stop. Allowable wear for
bolt securing Sta. 284 bellcrank to rubber stop is to surface of aluminum
transmission. Separate pivot pin on support. Stop (and support) may be
bellcrank from pitch control assem- rotated 90 degrees if stop is excessively
bly. worn at contact point. Replace rubber
stop if damaged, or if worn area cannot
(b). Rotate pitch control housing by hand; be rotated away from contact point.
check for rough, binding or hard
turning. Inspect for grease leakage. If NOTE: If replacement of stop support is re-
any of these conditions exist, remove quired, replace with onepiece stop support
pitch control assembly and inspect and retaining nut.
for further evidence of damage.
(3). Check aluminum support for condition
and wear. Replace aluminum support if
(c). Check that selfaligning bearing on damaged, or if excessive wear reduces
underside of pitch control housing is clearance between tail rotor blade and
adequately lubricated (packed tail boom to less than 0.50 inch (12.70
approximately 40 percent full) with mm) minimum. Measure allowable
grease (CM115), is movable and is clearance between tip of tail rotor blade
serviceable. and tail boom while holding hub
against support, and with assistant
(d). Ensure that pivot pin on Sta. 284 applying full right tail rotor pedal.
bellcrank is lubricated with grease
(CM115). Position bellcrank to NOTE: For any questionable items, refer to
engage pivot pin with pitch control complete and detailed inspection, damage,
assembly. Secure bellcrank to trans- wear and repair limits, and requirements
mission with bolt, washers, nut and for tail rotor assembly in COM.
cotter pin.
7. Tail Rotor Pitch Control Link Inspection
NOTE: For more detailed information, refer to
inspection, damage, wear and repair limits, Consumable Materials
and requirements for pitch control assembly (Ref. Section 910000)
(Ref. COM). Item Nomenclature
CM318 Primer
(11). Inspect for evidence of rotational
binding by handturning tail rotor
assembly a few turns while listening for (1). Maximum axial play for bearing in
unusual sounds. If condition is ques- pitch control link is 0.020 inch (0.508
tionable, perform applicable inspection. mm).
Page 206
Revision 34 643000
MAINTENANCE MANUAL
NOTE: Since bearing wear usually occurs only

at blade pitch control arm from displace- Consumable Materials
ment during operation, links can be re- (Ref. Section 910000)
versed and continued in service until either Item Nomenclature
or both bearings exceed wear tolerance. CM111 Grease, aircraft
(2). Replace pitch control link if worn CM217 Isopropyl alcohol
beyond 0.070 inch (1.778 mm) limit. If
wear area(s) are within limits, touch Special Tools
up with primer (CM318) and paint (Ref. (Ref. Section 910000)
Sec. 203000) at inspection. Item Nomenclature
ST608 Pitch control assembly holding block
8. Tail Rotor Conical Bearing Inspection
(1). Play is not permitted in conical drive
fork bearings (Ref. COM).
(1). Remove tail rotor from helicopter (Ref.
9. Tail Rotor Pitch Bearing Inspection 642000, Tail Rotor Hub and Fork
Replacement).
NOTE: In the following step, physical check for
pitch bearing wear that causes root fitting (2). Remove swashplate from helicopter
play on hub can be made by holding one (Ref. Tail Rotor Pitch Control Assembly
blade firmly and measuring flapping play at Replacement).
tip of opposite blade. Measured play indi-
cates combined wear of pitch bearings. (3). Remove pitch control links from
swashplate assembly.
(1). Maximum allowable pitch bearings play
is 0.250 inch (6.350 mm). Tail rotor swashplate bearings
CAUTION cannot be removed from hous-
10. Tail Rotor Swashplate Bearing Regreasing ing without damage to the bearings. If bear-
ings are removed from housing, install new
(Ref. Figure 205) bearings.
TAIL ROTOR SWASHPLATE

BEARING ASSEMBLY
REGREASE
TOOL
G643007
Figure 205. Tail Rotor Swashplate Bearing Regreasing
Page 207
643000 Revision 34
MAINTENANCE MANUAL
NOTE: For 4Bladed tail rotor swashplates, NOTE: The following procedure provides 100%
holding block (ST608) will need to be modi- grease fill. Normal grease fill is 20 to 40%.
fied. Accomplish modification, or build new Excess grease will extrude past seals for
block, as per Figure 207. several hours of operation until the proper
level is met.
(4). Using wrench (ST609) and holding
(8). Purge bearings with grease (CM111).
block (ST608), Remove nut and tang
washer from threaded end of swash- (a). Purge bearings slowly to prevent
plate. Discard tang washer. damage to outer seal.
(5). Carefully remove bearing grease seal at (b). Rotate bearings while greasing.
gearbox end of housing (seal will be (9). Remove plastic wedge (or equivalent
reused at reassembly). plug) and regreasing tool.
(6). Inspect seal for damage; no damage is (10). Hand rotate bearing to remove excess
allowed. grease.
NOTE: Ensure seal is serviceable. If new seal is
(7). Install regreasing tool (Ref. Figure 206) required, seals and bearings must come
and plug tang washer groove with from the same vendor.
locally fabricated plastic wedge (or
equivalent plug). (11). Install serviceable seal.
0.75 IN. (19.05 MM) A
0.25 IN. (6.35 MM)
1.56318 UNJS3B
THREADS PER MILS8879
3.00 IN.
(7.62 CM) 2.25 IN.
(5.715 CM)
MS150021 GREASE FITTING

SEAL MATERIAL 1/428 TAPER THREADS 0.093 IN.
(2.3622 MM) DIA THRU HOLE
0.50 IN.
SECTION AA
(12.70 MM) A
MATERIAL:
1. MATERIAL 6061T651 ALUM PER QQA250/11 OR EQUIVALENT.
2. SURFACE FINISH 125 RMS.
3. BREAK SHARP EDGES 0.0020.015 IN. (0.0510.381 MM).
4. CHEMICAL FILM TREAT PER MILC5541.
5. DIMENSIONAL TOLERANCE .030 IN. (0.762 MM); DIAMETERS TO BE G643006A
CONCENTRIC TO CENTERLINE WITHIN 0.002 IN. (0.051 MM).
Figure 206. Tail Rotor Swashplate Bearing Regreasing Tool
Page 208
Revision 21 643000
MAINTENANCE MANUAL
NOTE: Using a 5X to 10X magnifying glass, in- (14). Clean surface of locknut and swash-
spect tang washer center tang to ensure it is plate with a lintfree cloth dampened
acceptable (Ref. Figure 208). with alcohol (CM217).
(12). Install nut with a new tang washer.

Using wrench (ST609) and holding NOTE: Avoid getting torque seal in swashplate
block (ST608), torque nut to 550 600 splines.
(15). Apply a 0.125 inch (3.175 mm) wide
(13). Bend one tang of washer into any torque strip, using torque seal or
aligned slot on nut. equivalent, to surface of swashplate
assembly and locknut in two places
NOTE: Avoid getting alcohol in bearings. (Ref. Figure 208).
1.50 IN. 0.9801.010 IN.

(3.81 CM) (24.89225.654 MM)
0.62 IN. 0.50 IN.
(15.748 MM) (12.70 MM) .31 R 4 PLACES
0.9801.010 IN.
75 (24.89225.654 MM)
7.50 IN. 5.75 IN. 5.25 IN.

(19.05 CM) (14.605 CM) 13.335 CM)
2.25 IN. 2.62 IN.

(5.715 CM) (6.6548 CM)
DIA THRU 0.50 IN.
(12.70 MM)
1.13 IN.
0.06 R TYP (2.8702 CM)
1.50 IN.
0.88 IN. (3.81 CM) 3.00 IN.
(22.352 MM) (7.62 CM)
MODIFICATION OF 369D298223 HOLDING BLOCK FOR USE

WITH 4 BLADED PITCH CONTROL ASSEMBLY (369D21820).
G643008A
Figure 207. Tail Rotor Swashplate Holding Block
Page 209
643000 Revision 21
MAINTENANCE MANUAL
TORQUE STRIPE
LOCATIONS
ACCEPTABLE
UNACCEPTABLE
G643009
Figure 208. Tang Washer Inspection and Application of Torque Stripe
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Revision 21 643000
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Chapter
67
Flight Controls
MAINTENANCE MANUAL
TABLE OF CONTENTS
670000 Flight Controls (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Main Rotor Flight Control System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. AntiTorque Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3. AntiTorque and Control System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4. Stability Augmentation System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Main Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 102. Isolating Main Rotor Control System Troubles . . . . . . . . . . . . . . . . . . . 103
Table 103. Isolating Tail Rotor Control System Troubles . . . . . . . . . . . . . . . . . . . . 104
Table 104. Antitorque Fan System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 101. YSAS Electrical Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 102. YSAS Troubleshooting (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 103. YSAS Ground Test Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
671000 Main Rotor Flight Controls (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Collective Mixer, Lateral and Longitudinal Mixer (TunnelRouted)
Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Controls Support Bracket and Bellcranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Collective Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Pilots Collective Pitch Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Copilots Collective Pitch Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Collective Pitch Stick Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Collective Control Interconnecting Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. Inboard Collective Stick Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J. Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. Pilots Cyclic Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
L. Copilots Cyclic Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
M. Pilots Compartment Lateral and Longitudinal Cyclic Control Linkage . . . . . . . 3
N. OneWay Lock Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O. Cyclic Trim Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P. RoofMounted Control Rods (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Q. RoofMounted Bellcranks (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1. Main Rotor and Control System (369D/E/FF 500N) . . . . . . . . . . . . . . 4
Figure 2. Main Rotor and Control System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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MAINTENANCE MANUAL

1. TunnelRouted Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. TunnelRouted Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. TunnelRouted Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. RoofMounted Control Rod Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. RoofMounted Control Rod Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. TunnelRouted Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. RoofMounted Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. RoofMounted Control Rod Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. RoofMounted Bellcrank Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. RoofMounted Bellcrank Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. RoofMounted Bellcrank Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Link Assembly Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Link Assembly Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Link Assembly Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Controls Support Bracket and Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Controls Support Bracket and Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403. Controls Support Bracket, Idler Bellcranks and Cyclic Trim
Actuators Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Controls Support Bracket and Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . 406
6. Pilots Collective Pitch Stick Replacement (L/H Command) . . . . . . . . . . . . . . . . . . . . 406
A. Pilots Collective Pitch Stick Removal (L/H Command) . . . . . . . . . . . . . . . . . . . . . . 406
Figure 404. Dual Collective Controls (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . 407
B. Pilots Collective Pitch Stick Installation (L/H Command) . . . . . . . . . . . . . . . . . . . 408
7. Pilots Collective Pitch Stick Replacement (R/H Command) . . . . . . . . . . . . . . . . . . . . 408
A. Pilots Collective Pitch Stick Removal (R/H Command) . . . . . . . . . . . . . . . . . . . . . . 408
B. Pilots Collective Pitch Stick Installation (R/H Command) . . . . . . . . . . . . . . . . . . . 408
Figure 405. Dual Collective Controls (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . 409
8. Copilots Collective Pitch Stick Replacement (L/H Command) . . . . . . . . . . . . . . . . . . 410
A. Copilots Collective Pitch Stick Removal (L/H Command) . . . . . . . . . . . . . . . . . . . . 410
B. Copilots Collective Pitch Stick Installation (L/H Command) . . . . . . . . . . . . . . . . . 410
Figure 406. CoPilots Collective Stick Assembly Installation (L/H Command) . 410
9. Copilots Collective Pitch Stick Replacement (R/H Command) . . . . . . . . . . . . . . . . . . 411
A. Copilots Collective Pitch Stick Removal (R/H Command) . . . . . . . . . . . . . . . . . . . . 411
B. Copilots Collective Pitch Stick Installation (R/H Command) . . . . . . . . . . . . . . . . . 411
Page ii
MAINTENANCE MANUAL

10. Collective Control Interconnecting Torque Tube Replacement . . . . . . . . . . . . . . . . . . 411

A. Collective Control Interconnecting Torque Tube Removal . . . . . . . . . . . . . . . . . . . 411
B. Collective Control Interconnecting Torque Tube Installation . . . . . . . . . . . . . . . . . 412
11. Collective Bungee Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Collective Bungee and OverCenter Fitting Removal . . . . . . . . . . . . . . . . . . . . . 412
Figure 407. Collective Torque Tube, Gas Producer Torque Tube and
Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 408. Inboard Collective Stick Socket Assembly (L/H Command) . . . . . . . 414
B. Collective OverCenter Fitting and Bungee Installation and
Preliminary Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
12. Inboard Collective Stick Socket Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 415
A. Inboard Collective Stick Socket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Inboard Collective Stick Socket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 415
13. Cyclic Control Stick Replacement (Inboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Cyclic Control Stick Removal (Inboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Cyclic Control Stick Installation (Inboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 409. Cyclic Stick Assembly Installation (Inboard) . . . . . . . . . . . . . . . . . . . . 417
14. Cyclic Control Stick Replacement (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Cyclic Control Stick Removal (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Cyclic Control Stick Installation (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Figure 410. Cyclic Stick Assembly Installation (Outboard) . . . . . . . . . . . . . . . . . . 418
15. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Replacement
(L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Removal
(L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Installation
(L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 411. Cyclic Controls (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
16. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Replacement
(R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Removal
(R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Installation
(R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
17. Cyclic Pitch Interconnecting Torque Tube Replacement (L/H Command) . . . . . . . . 420
A. Cyclic Pitch Interconnecting Torque Tube Removal (L/H Command) . . . . . . . . . . 420
Figure 412. Cyclic Torque Tube and OneWay Lock Installation . . . . . . . . . . . . . 421
B. Cyclic Pitch Interconnecting Torque Tube Installation (L/H Command) . . . . . . . 422
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MAINTENANCE MANUAL

18. Cyclic Pitch Interconnecting Torque Tube Replacement (R/H Command) . . . . . . . . 422
A. Cyclic Pitch Interconnecting Torque Tube Removal (R/H Command) . . . . . . . . . . 422
B. Cyclic Pitch Interconnecting Torque Tube Installation (R/H Command) . . . . . . . 422
19. OneWay Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. OneWay Lock Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. OneWay Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
20. Cyclic Trim Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Cyclic Trim Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Cyclic Trim Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Cyclic and Collective Control System Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Collective Controls Rigging (L/H Command) (369D/E/FF 500N) . . . . . . . . . . . . . . 501
Figure 501. Main Rotor Control System Rigging (369D/E/FF 500N)
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Figure 502. Rigging Main Rotor Control System (600N) (Sheet 1 of 3) . . . . . . . . 505
Figure 503. Cyclic and Collective Controls Rigging Tools (R/H Command) . . . . . 508
3. Collective Controls Rigging (R/H Command) (369D/E/FF 500N) . . . . . . . . . . . . . . 509
4. Collective Control System Rigging (L/H Command) (600N) . . . . . . . . . . . . . . . . . . . . 509
5. Collective Controls Rigging (R/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . 510
6. Cyclic Controls Rigging (L/H Command) (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . 510
7. Cyclic Controls Rigging (R/H Command) (369D/E/FF 500N) . . . . . . . . . . . . . . . . . 513
8. Cyclic Controls Rigging (L/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
9. Cyclic Controls Rigging (R/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
10. Gas Producer Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Figure 504. Gas Producer Drive Backlash Adjustment
(Outboard Collective Stick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Figure 505. Gas Producer Drive Backlash Adjustment
(Inboard Collective Stick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
11. Pipe Plug Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
12. Gas Producer Interconnecting Torque Tube Assembly Shimming
(0003D thru 0929D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Figure 506. Gas Producer Interconnecting Torque Tube Shimming Procedure
(0003D thru 0929D) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
13. Collective Stick Friction Mechanism Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Figure 507. Collective Stick Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
14. Collective Bungee Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
15. Cyclic Trim Actuator Bench Testing (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . 524
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MAINTENANCE MANUAL

16. Cyclic Trim Actuator Bench Testing (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Figure 508. Cyclic Trim Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Figure 509. Cyclic Trim Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Figure 510. Wiring Diagram and Cable Routing (Collective Stick) . . . . . . . . . . . . 529
Figure 511. Wiring Diagram and Cable Routing (Cyclic Stick) . . . . . . . . . . . . . . . 530
1. TunnelRouted Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. TunnelRouted Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 602
2. Controls Support Bracket and Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
3. Pilots Collective Pitch Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Copilots Collective Pitch Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Collective Stick Friction Mechanism Operational Check . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Outboard Collective Stick Inspection (L/H Command) . . . . . . . . . . . 604
Figure 603. Outboard Collective Stick Inspection (R/H Command) . . . . . . . . . . . 605
6. Collective Control Interconnecting Torque Tube Inspection . . . . . . . . . . . . . . . . . . . . 606
7. Collective Bungee Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
8. Inboard Collective Stick Socket Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 606
9. Pilots Cyclic Control Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
10. Copilots Cyclic Control Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
11. OneWay Lock Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
12. Cyclic Trim Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
13. Cyclic Control System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 604. Cyclic Stick and Friction Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
14. Main Rotor Flight Control System 600Hour Inspection . . . . . . . . . . . . . . . . . . . . . . 609
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. TunnelRouted Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. TunnelRouted Control Tube Inspection and Sleeve Installation . . . . . . . . . . . . . . . 801
A. Control Tube End Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Sleeve Fabrication and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Table 801. Control Tube ReIdentification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
B. Control Tube Straight Area Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Table 802. Control Tube Straight Area Repair Limits . . . . . . . . . . . . . . . . . . . . . . . 804
3. Controls Support Bracket and Bellcrank Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 805
4. Controls Support Bracket and Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5. Controls Support Bracket and Bellcrank Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 805
6. Pilots Collective Pitch Stick Disassembly (L/H Command) . . . . . . . . . . . . . . . . . . . . 805
Figure 802. Control Tube Boot Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
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7. Pilots Collective Pitch Stick Repair (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8. Pilots Collective Pitch Stick Reassembly (L/H Command) . . . . . . . . . . . . . . . . . . . . . 807
9. Pilots Collective Pitch Stick Disassembly (R/H Command) . . . . . . . . . . . . . . . . . . . . 808
10. Pilots Collective Pitch Stick Reassembly (R/H Command) . . . . . . . . . . . . . . . . . . . . . 808
11. Copilots Collective Pitch Stick Disassembly (L/H and R/H Command) . . . . . . . . . . 809
12. Copilots Collective Pitch Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
13. Copilots Collective Pitch Stick Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
14. Collective Control Interconnecting Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . 810
15. Collective Bungee Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
16. Collective Bungee Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
17. Inboard Collective Stick Socket Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 811
18. Inboard Collective Stick Socket Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
19. Inboard Collective Stick Socket Assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 812
20. Cyclic Control Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
21. Cyclic Friction Mechanism Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
22. Lateral Control Rods and Sta. 67 Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
23. Cyclic Pitch Interconnecting Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
24. OneWay Lock Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
25. Cyclic Trim Actuator Spring Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 814
26. Cyclic Trim Actuator Housing or Trim Tube Replacement . . . . . . . . . . . . . . . . . . . . . 815
27. Cyclic Trim Actuator (Motor/Gear Drive Mechanism) Replacement . . . . . . . . . . . . . 815
28. Cyclic Trim Actuator Rework (Calco P/N 8222M6 and 8222M7) . . . . . . . . . . . . . . . . 815
671020 Collective and Cyclic Stick Grips (369D/E/FF 500/600N) . . . . . . . . . . . . . A
1. Collective Pitch Stick Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Collective Pitch Stick Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cyclic Stick Grip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Cyclic Control Stick Grip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cyclic Control Stick Grip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cyclic Control Stick Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Collective Pitch Stick Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Cyclic Stick Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Cyclic Stick Grip Disassembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 204
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5. Cyclic Stick Grip Switch Replacement (Standard Grip) . . . . . . . . . . . . . . . . . . . . . . . . 206

6. Cyclic Stick Grip Disassembly (Optional TGrip, PN 369D297846 Only) . . . . . . . . 207
7. Cyclic Stick Grip Reassembly and Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Rework of Cyclic Stick Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
672010 AntiTorque Flight Controls (Two and Four Blade) (369D/E/FF) . . . . . . A
1. Tail Rotor Control Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Upper Fuselage and Tailboom Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 101. Tail Rotor and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Sta. 120 Control Rod or Sta. 142 Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . 401
A. Sta. 120 Control Rod or Sta. 142 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Sta. 120 Control Rod or Sta. 142 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage . . . . . . . . . . . 402
2. Sta. 284 Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Sta. 284 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Sta. 284 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Tailboom Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Tailboom Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Tailboom Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Sta. 95 Bellcrank and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Sta. 95 Bellcrank and Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Tail Rotor Pedal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 404
B. Sta. 95 Bellcrank and Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
C. Tail Rotor Pedal Assembly General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
D. CoPilots Pedal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5. Tail Rotor Pedal Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Tail Rotor Pedal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Tail Rotor Pedal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
6. Dual Tail Rotor Pedal Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Tail Rotor Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Rigging Tail Rotor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
2. Tail Rotor Bungee Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Tail Rotor Bungee Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
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1. Upper Fuselage and Tailboom Control Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 601
2. Tail Rotor Pedal Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Table 601. Isolating Control System Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Floor and TunnelRouted Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. FloorRouted Tail Rotor Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Upper Fuselage and Tailboom Control Linkage Repair . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Rework of Sta. 142 Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . 803
4. Station 78.50 Tail Rotor (TunnelRouted) Control Rod . . . . . . . . . . . . . . . . . . . . . . . . 803
A. Tail Rotor Idler Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5. Tail Rotor Pedal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
6. Tail Rotor Pedal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
7. Tail Rotor Pedal Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8. Tail Rotor Bungee Spring Forward Attachment Relocation . . . . . . . . . . . . . . . . . . . . 804
Figure 802. Relocation of Tail Rotor Bungee Spring Forward Attachment . . . . . 805
672030 NOTAR) AntiTorque System Flight Controls (500/600N) . . . . . . . . . . . . . A
1. NOTAR AntiTorque System Control Linkages Configuration and Description . . 1
2. Stability Augmentation System Description and Operation . . . . . . . . . . . . . . . . . . . . 1
3. 500NM7301 YSAS Fin Position Indicator (U.K. Only) . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1. 500NM7301 YSAS Fin Position Indicator Components . . . . . . . . . . . . . . 2
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. AntiTorque Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Upper Fuselage Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket Removal . 401
B. Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Forward Directional Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Forward Directional Control Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Forward Directional Control Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
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4. Splitter Bungee Spring Replacement (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Splitter Bungee Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Splitter Bungee Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5. Upper Fuselage Station 113.00 Splitter Assembly and Bellcrank Replacement . . 402
A. Station 113.00 Splitter Assembly and Bellcrank Removal . . . . . . . . . . . . . . . . . . . 402
B. Station 113.00 Splitter Assembly and Bellcrank Installation . . . . . . . . . . . . . . . . 402
6. Intermediate Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Intermediate Control Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. AntiTorque Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Intermediate Control Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7. Station 137.50 Support Bracket and Bellcrank Replacement . . . . . . . . . . . . . . . . . . . 404
A. Station 137.50 Support Bracket and Bellcrank Removal . . . . . . . . . . . . . . . . . . . . 404
B. Station 137.50 Support Bracket and Bellcrank Installation . . . . . . . . . . . . . . . . . . 404
8. Fan Pitch Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Fan Pitch Control Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fan Pitch Control Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9. Forward Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Forward Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 1 of 2) . . . . . . . . 407
B. Forward Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
10. Center Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Center Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Center Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
11. Aft Control Rod Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Aft Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Aft Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
12. Sector Assembly and Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Sector Assembly and Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Sector Assembly and Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
13. Drum Assembly and Idler Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Drum Assembly and Idler Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Drum Assembly and Idler Pulley Installation (500N) . . . . . . . . . . . . . . . . . . . . . . . 412
C. Drum Assembly and Idler Pulley Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . 412
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14. AntiTorque Pedal Friction Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. AntiTorque Pedal Friction Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. AntiTorque Pedal Friction Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
15. AntiTorque Pedal Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. AntiTorque Pedal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 403. Pedal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. AntiTorque Pedal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
16. Stability Augmentation System (S.A.S.) Actuator Replacement . . . . . . . . . . . . . . . . 415
A. S.A.S. Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. S.A.S. Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
17. S.A.S. Rate Gyro and Electronic Control Box (Computer) Replacement . . . . . . . . . 415
A. S.A.S. Rate Gyro and Electronic Control Box (Computer) Removal . . . . . . . . . . . 416
B. S.A.S. Rate Gyro and Electronic Control Box (Computer) Installation . . . . . . . . 416
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Directional Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Fan Pitch Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Fan Pitch Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
3. Pilot Pedal Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Pilot Pedal Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4. AntiTorque Pedal Friction Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 505
5. Thruster Control Rigging (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Figure 503. Thruster Control Rigging (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 506
6. Thruster Control Rigging (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
7. Left Vertical Stabilizer Assembly Rigging (500N, and 600N with YSAS) . . . . . . . . 508
8. Stability Augmentation System Rigging Instructions
(500N, and 600N with YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
9. Vertical Stabilizer Assembly Rigging (600N without YSAS System) . . . . . . . . . . . . 509
Figure 504. Left Vertical Stabilizer Rigging (500N, and 600N with YSAS) . . . . 510
Figure 505. Stability Augmentation System S.A.S. (Sheet 1 of 2) . . . . . . . . . . . . 511
Figure 506. Vertical Stabilizer Rigging (600N without YSAS) . . . . . . . . . . . . . . . . 513
Page x
MAINTENANCE MANUAL

10. Vertical Stabilizer Trim Tab Adjustment and Tool Manufacturing
(600N without YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
A. Trim Tab Tool Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
B. Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Figure 507. Vertical Stabilizer Trim Tab Bending Tool . . . . . . . . . . . . . . . . . . . . . . 515
Table 501. Flight Controls Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
1. Upper Fuselage and Tailboom Control Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 601
2. AntiTorque Pedal Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket Inspection . . 601
4. Forward and Intermediate Directional Control Tube, and Link Inspection . . . . . . 601
5. Splitter Bungee Spring Inspection (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6. Sta. 113.00 Splitter Assembly and Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . 602
7. Forward and Center Cable Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
8. YSAS Actuator, Rate Gyro and Electronic Control Box Inspection . . . . . . . . . . . . . . 602
9. Fan Pitch Control Tube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Isolating Control System Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601. Control Cable Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Forward and Center Cable Relief Area Inspection . . . . . . . . . . . . . . . 604
Figure 603. Control Cable Telescopic Swivel End Inspection . . . . . . . . . . . . . . . . . 605
10. Sector Assembly, Control Cables and Drum Assembly Inspection . . . . . . . . . . . . . . . 606
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. AntiTorque Flight Control Repair General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket Repair . . . . . 801
3. Forward Directional Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Upper Fuselage Sta. 113.00 Splitter Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . 801
5. Intermediate Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
6. Sta. 137.50 Support Bracket and Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
7. Fan Pitch Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8. Forward Cable Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
9. Center Cable Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Page xi
MAINTENANCE MANUAL

10. Aft Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
11. Thruster Sector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
12. Drum Assembly and Idler Pulleys Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
13. AntiTorque Pedal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
14. AntiTorque Pedal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
15. AntiTorque Pedal Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
16. YSAS Actuator Regrease Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
A. YSAS Actuator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
B. YSAS Actuator Regrease and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 801. YSAS Actuator (CrossSection View) . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Page xii
MAINTENANCE MANUAL
Section
670000
Flight Controls
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
FLIGHT CONTROLS
FAULT ISOLATION
1. Main Rotor Flight Control System tube, tunnelrouted control tube, Sta. 120
Troubleshooting control tube and tail boom control rod trans-
mitting input through a series of bellcranks
Ensure that rotor controls are
CAUTION not struck by any object. Many
and idlers.
of the components are highly stressed and 3. AntiTorque and Control System
must not be returned to service if surface Troubleshooting
damage occurs. When maintenance work is
performed near engine air inlet, comply Troubleshooting information is divided into (1)
with precautions (Ref. Chap. 71) to prevent investigation of operational vibration problems
entry of foreign objects. originating with the tail rotor or symptoms
that can be recognized (Ref. Chap. 64) and (2)
Troubleshooting information is divided into: (1) isolation and localization of an unusual
investigation of main rotor vibrations (Ref. controls malfunction (Ref. Table 103 or
Chap. 62); (2) investigation of symptoms (Ref. Table 104).
Table 101); and (3) isolation of troubles (Ref.
Table 102). 4. Stability Augmentation System
Troubleshooting
First determine which major installation is
defective. Isolate each linkage installation Troubleshooting the Yaw Stability Augmenta-
from others until area of malfunction is tion System (YSAS) shall be performed using
located. Then investigate and determine exact the wiring diagram (Ref. Figure 101) in
location of malfunction and repair or replace conjunction with the fault isolation tree (Ref.
defective component(s). Since first indication of Figure 102) and the ground test box (Ref.
trouble usually is felt at cyclic or collective Figure 103).
pitch stick, isolation procedures in Table 101
and Table 102 begin with symptoms detected Troubleshooting the YSAS by field mainte-
during operation of these controls. nance personnel shall be limited to isolating
the trouble to a malfunctioning or defective
Sudden onset of excessive system unit/component.
WARNING and/or unusual main rotor
vibrations should be investigated as to For removal or replacement of YSAS compo-
cause, prior to continued flight. Under nents refer to applicable section.
no circumstance should main rotor
tracking be attempted to correct the Death or injury can occur if
problem until a thorough inspection of WARNING proper safety precautions
the main rotor blades, hub assembly are not taken while performing electri-
and strap pack assembly has been per- cal system checks with electrical pow-
formed. er on.
2. AntiTorque Flight Controls Maintenance personnel other

CAUTION than approved manufacturers
AntiTorque flight controls consist of antitor- representative shall not attempt to repair
que pedals, torque tube, floorrouted control any part of the YSAS system.
Page 101
670000 Revision 30
MAINTENANCE MANUAL
Table 101. Troubleshooting Main Rotor Controls
Cyclic stick pressure in one Check for continuity between pin S If continuity exists, replace cyclic trim
direction; hands off condition and pins R, U, V, and X of switch, Cyclic Stick Grip Switch
stick drifts in direction of connector(s) P109 and/or P130. Replacement (Standard Grip).
pressure.
Symptom remains. Isolate wiring to circuit components. If short exists, repair as necessary. If
Check for short circuit between ground short does not exist, replace cyclic trim
and suspect trim mode circuit. actuator.
Cyclic control stick pressures Trim actuator inoperative. Replace actuator.

cannot be reduced by
operating trim switch. Defective components in trim actuator Troubleshoot control circuits: replace
control circuit. defective electrical component(s).
Trim change is too slow. Defective trim actuator. Replace actuator.
Cyclic control sticks have Low fluid in oneway lock fluid Add fluid to oneway lock reservoir.
tendency to move to aft reservoir.
position.
Inadequate cyclic control Helicopter loaded out of center of Check and correct weight and
during flight. gravity range. balance.
Incorrect cyclic rigging. Correct cyclic rigging.
Excessive pressure required Lateral and/or longitudinal friction Loosen lateral and/or longitudinal
for lateral and/or longitudinal device improperly adjusted. friction device.
movement of cyclic control
stick on ground and during Swashplate spherical bearing surface Replace swashplate bearing assembly
flight. (Some droop friction is damaged. if torque required to rotate bearing
always felt when there is no exceeds 32 inchpounds (3.61 Nm).
rotor rpm.) Scissors crank bearings or hub lower Replace defective bearings.
shoe bearings binding or frozen.
Lateral and/or longitudinal Realign rod end bearing.

interconnecting rod end bearing
binding due to incorrect alignment.
Droop stop plungers sticking. Clean plungers and mating shoe

bushings with isopropyl alcohol
(CM217).
Droop stop followers, rollers and/or Apply rust inhibitor and lubricants
stop ring rusty or corroded. (CM204) to followers, rollers and
droop stop ring.
Droop stop striker plate(s) or cam Replace striker plate and/or cam roller.
roller(s) damaged.
Oneway lock check valve, or push Replace oneway lock assembly.

rod shaft that unseats the valve, is
galled or seized.
Page 102
Revision 21 670000
MAINTENANCE MANUAL
Table 102. Isolating Main Rotor Control System Troubles

Binding, lockingup and Disconnect oneway lock. If symptom gone, replace oneway
erratic action of cyclic control lock.
stick.
Symptom remains. Disconnect upper ends of longitudinal If symptom gone and rod ends are
and lateral control rods. serviceable, disassemble and inspect
main rotor mixer controls until
defective part is located.
Symptom remains. Reconnect upper ends of longitudinal If symptom gone and rod ends are
and lateral control rods, and serviceable, disassemble and inspect
disconnect lower ends. pilot compartment controls until
Trouble corrected (Reconnect all control linkage).
Binding, lockingup and CAUTION: Before disconnecting collective pitch control rod, install collective
erratic action of collective bungee installation tool (ST508) to prevent spring reaction on control rod.
control stick.
Disconnect upper end of collective If symptom gone and rod end is
pitch control rod and operate stick. serviceable, disassemble and inspect
main rotor mixer controls until
Symptom remains. Leave upper end of collective pitch Trouble is in pilot compartment
control rod disconnected. collective control linkage.
Symptom remains. WARNING: Do not disconnect any hardware from pilots collective stick unless
collective bungee installation tool (ST508) is installed. Strong bungee spring
pressure can cause linkage reaction and severe personal injury, or parts
damage.
Disconnect gas producer control rod If symptom gone, trouble is in engine

from collective stick. Disconnect droop controls.
control override link from collective
controls torque tube.
Symptom remains. Leave gas producer control rod and Disassemble and inspect pilot
droop control override link compartment collective control linkage
disconnected. until defective part is located.
Trouble corrected (Reconnect all control linkage)
Page 103
670000 Revision 21
MAINTENANCE MANUAL
Table 103. Isolating Tail Rotor Control System Troubles

Binding, locking up and erratic Disconnect pitch control links from If symptom gone, replace tail rotor
action of foot pedals. (Do not pitch control assembly. assembly or repair (Ref. COM).
force controls)
Symptom remains. Disconnect Sta. 284 aft boom If symptom gone, clean swashplate
bellcrank from pitch control assembly. bore and output shaft splines.
Lubricate splines. Replace swashplate
if necessary. Check for elongation of
bolt hole in support arm portion of
main housing assembly of tail rotor
gear box, caused by looseness of
bellcrank fulcrum bolt and nut. Repair
(Ref. COM).
Symptom remains. Disconnect floorrouted tail rotor If symptom gone, inspect tail rotor
control rod from foot pedal torque tube control rods and bellcranks until
fitting. defective part is located.
Symptom remains. Loosen foot pedal torque tube If symptom gone, pedal torque tube
brackets mounted on front of floor misaligned; shim for correct alignment.
structure. If symptom remains, disassemble and
inspect tail rotor foot pedal installation
until defective part is located (same
section).
Trouble corrected.
Table 104. Antitorque Fan System Troubleshooting

Excessive resistance against Binding in controls linkage. Isolate damage or obstruction and
pedal movements. remove.
Restriction against rotating cone. Isolate restriction or damage and
remove.
Binding, locking up or erratic Control rod or cable restrictions or Inspect control rod and control cable
action of pedal movement. misalignment. connections, rod end condition and
bearing movement, replace
components as required.
Pedals feel rachety. Flat spotting on thruster rollers. Replace rollers (Ref. Sec. 534030).
Degraded movement or Restriction or malfunction at splitter Inspect splitter range and freedom of
response of fan control assembly. movement.
linkage.
Degraded travel of force limiting Isolate damage or malfunction and
control rod or diffuser bellcrank replace components.
connections.
Incorrect rigging. Correct rigging.
Inadequate antitorque/direc- Incorrect rigging. Correct rigging.
tional movement or response
during flight.
Page 104
Revision 29 670000
MAINTENANCE MANUAL
TAILBOOM RING FRAME

SAS ELECT CONTROL DISCONNECT DISCONNECT
(COMPUTER) P1 J2P J3P P4 (YSAS ACTUATOR)
28VDC OUT R SAS2A20 J SAS2B20 J SAS2C20 J 28VDC PWR
28V RTN Z SAS9A20 K SAS9B20 K SAS9C20 K PWR END
ACTUATOR ENABLE D SAS3A22 L SAS3B22 L SAS3C22 L ACTUATOR ENABLE
SERVO CONTROL SIGNAL H SAS4A22 WHT S SAS4B22 WHT S SAS4C22 WHT S COMMAND SIG (L)
SERVO CONTROL RTN J SAS4A22 BLU A SAS4B22 BLU A SAS4C22 BLU A COMMAND SIG (H)
SHIELD K N N
ACTUATOR POSITION L SAS5A22 WHT B SAS5B22 WHT B SAS5C22 WHT B POSITION FEEDBACK (H)
RTN M SAS5A22 BLU P SAS5B22 BLU P SAS5C22 BLU P POSITION FEEDBACK (L)
SHIELD N R SAS5B22 R
+15VDC P SAS6A22 WHT C SAS6B22 WHT C SAS6C22 WHT C +15VDC
COM R SAS6A22 BLU D SAS6B22 WHT D SAS6C22 BLU D SIGNAL COMMON
15VDC G SAS6A22 ORN E SAS6B22 ORN E SAS6C22 ORN E 15VDC
SHIELD H G G
SAS10A22 F SAS10B22 F SAS10C22 F CHASSIS GND
28VDC RTN B E40

CHASSIS GRND E C B A
SAS7A20N
28VDC IN M SAS8A20N CB121
ON/OFF RELAY C J1202P YSAS
YSAS
2 5A 1
SAS1B20 Z SAS1A20 S12 E31
SAS15B22 A SAS15A22 SAS16A22N S
3 2
ACTUATOR PCS TP E
SERVO COM TP S
HARD OVER TP A
SIGNAL COMMON W
LATERAL ACCEL TP F
YAW RATE TP G
YAW RATE IN + B
YAW RATE IN C
SHIELD N P5 (YAW RATE GYRO)
28VDC OUT P
28V RTN Q D SIG OUT (H)
SAS11A22 WHT
15VDC F C SIG OUT (L)
SAS11A22 BLU
+15VDC T
SAS12A22 A +28VDC
SAS13A22 B PWR GND
SAS14A22 E 15VDC
SAS17A22 F +15VDC
500N
G6720161C
Figure 101. YSAS Electrical Diagram (Sheet 1 of 2)
Page 105
670000 Revision 42
MAINTENANCE MANUAL
TAILBOOM RING FRAME

DISCONNECT DISCONNECT
SAS ELECT CONTROL P515 (YSAS ACTUATOR)
J513P J514P
(COMPUTER) P512
SAS3A22 L SAS3B22 L SAS3C22 L ACTUATOR ENABLE
28VDC OUT R SAS2A16 SAS2A20 J SAS2B20 J SAS2C20 J 28VDC PWR
28V RTN Z SAS9A20 K SAS9B20 K SAS9C20 K PWR GND
ACTUATOR ENABLE D SAS4A22 WHT
SERVO CNTR SIG H SAS4A22 BLU S SAS4B22 WHT S SAS4C22 WHT S COMMAND SIG (L)
SERVO CNTR RTN J A SAS4B22 BLU A SAS4C22 BLU A COMMAND SIG (H)
SHIELD K SAS5A22 WHT N N
ACTUATOR POS L SAS5A22 BLU B SAS5B22 WHT B SAS5C22 WHT B POSITION FEEDBACK (H)
RTN M P SAS5B22 BLU P SAS5C22 BLU P POSITION FEEDBACK (L)
SHIELD N SAS6A22 WHT R R
+15VDC P SAS6A22 BLU C SAS6B22 WHT C SAS6C22 WHT C +15VDC
COM R SAS6A22 ORN D SAS6B22 BLU D SAS6C22 BLU D SIGNAL COMMON
15VDC G E SAS6B22 ORN E SAS6C22 ORN E 15VDC
SHIELD H SAS7A20 G G
28VDC RTN B SAS10A22N
SAS8A22N
CHASSIS GND E F SAS10B22 F SAS10C22 F CHASSIS GND
A B C G SPARE
ACTUATOR POS TP E E40 H CURRENT MONITOR
M PULSE WIDTH MODULATOR
SERVO COM TP S N SPARE
HARD OVER TP A J1202P S12 R SPARE
SIGNAL COM W A SAS15A20 SAS16A22N (E31J)
3 2
LATERAL ACCEL TP F J1201P
YAW RATE TP G CB121
SAS15B20 5A 1
ON/OFF RELAY C Z SAS1A20 2
SAS18A22 WHT 71
SAS18A22 BLU 72
P5 (YAW RATE GYRO)
SAS1B20 D SIG OUT (H) 74
28VDC IN M
C SIG OUT (L)
F +15VDC
A +28VDC
B PWR GND
SHIELD N SAS11A22 WHT E 15VDC E33
YAW RATE IN + B SAS11A22 BLU
YAW RATE IN C N
SAS17A22
+15VDC T SAS12A22
28VDC OUT P SAS13A22 YSAS INDICATOR TB5039
28V RTN Q SAS14A22 (L) SIGNAL RED M L SAS18B22 BLU
15VDC F
(H) SIGNAL BLK S R SAS18B22 WHT
TB5034
BLU A
28VDC LIGHT
E35
BRN P
600N
G6720162A
Figure 101. YSAS Electrical Diagram (Sheet 2 of 2)
Page 106
Revision 42 670000
MAINTENANCE MANUAL
START
VERIFY ALL YSAS SYSTEM ASSOCIATED

ELECTRICAL CONNECTORS ARE MATED WITH NO
COMPONENTS. VERIFY CIRCUIT BREAKER IS GO TO SHEET 2
PUSHED IN AND YSAS SYSTEM ON/OFF SWITCH IS
ON. IS YSAS STILL INOPERATIVE?
YES
SHUT OFF ELECTRICAL POWER. CHECK FOR

REPAIR OPEN WIRE(S) BETWEEN PIN B
CONTINUITY TO A/C GROUND AT PINS B, E AND NO
OF SAS COMPUTER AND GROUND
C OF SAS COMPUTER PLUG (P1 FOR 500N: P512
E40B OR PIN E AND GROUND E40A
FOR 600N). DOES CONTINUITY EXIST?
OR PIN C AND GROUND E31S.
YES
SHUT OFF ELECTRICAL POWER. DISCONNECT NO

SAS COMPUTER PLUG (P1 FOR 500N: P512 FOR REPAIR OPEN WIRE BETWEEN PIN M
600N). REAPPLY ELECTRICAL POWER AND OF SAS COMPUTER AND CB121.
CHECK FOR 28 VDC AT PIN M. IS VOLTAGE
PRESENT?
YES
DISCONNECT ELECTRICAL POWER. CONNECT

SAS TEST BETWEEN SAS COMPUTER AND SAS NO
WIRE HARNESS. REAPPLY ELECTRICAL POWER
REPLACE FAULTY SAS COMPUTER
AND AT SAS TEST BOX, CHECK FOR +15 VDC
AND 15 VDC COMING FROM COMPUTER
POWER SUPPLY. IS VOLTAGE PRESENT?
YES
REMOVE YAW RATE GYRO ATTACHING HARDWARE

AND CAREFULLY ROTATE GYRO IN A CLOCKWISE NO
DIRECTION. CHECK RIGHT VERTICAL STABILIZER FOR GO TO SHEET 3
TRAILING EDGE LEFT (INITIAL MOVEMENT ONLY). DOES
RIGHT VERTICAL STABILIZER MOVE?
YES
REMOVE SAS COMPUTER ATTACHING HARDWARE

AND CAREFULLY TILT COMPUTER, CONNECTOR NO
SIDE UP, CHECK RIGHT VERTICAL STABILIZER GO TO SHEET 4
TRAILING EDGE RIGHT MOVEMENT. DOES RIGHT
VERTICAL STABILIZER MOVE?
YES
YAW SAS SYSTEM APPEARS TO OPERATE

CORRECTLY.
G6720171A
Figure 102. YSAS Troubleshooting (Sheet 1 of 4)
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670000 Revision 30
MAINTENANCE MANUAL
FROM SHEET 1
DOES RIGHT VERTICAL STABILIZER MOVE OR NO

YAW SAS SYSTEM APPEARS TO
OSCILLATE WITH NO SENSOR INPUTS? OPERATE CORRECTLY.
YES
SHUT OFF ELECTRICAL POWER. CONNECT SAS NO SHUT OFF ELECTRICAL POWER. CHECK NO REPAIR OPEN WIRES BETWEEN YSAS
TEST BOX BETWEEN SAS COMPUTER AND SAS FOR OPEN WIRES BETWEEN YSAS COMPUTER AND RIGHT VERTICAL
WIRE HARNESS. REAPPLY ELECTRICAL COMPUTER AND RIGHT VERTICAL STABILIZER ACTUATOR.
POWER. CHECK FOR SERVO COMMAND SIGNAL STABILIZER WIRE HARNESS. DOES
AT TEST BOX BETWEEN SERVO TEST POINT CONTINUITY EXIST?
AND TEST BOX GROUND. IS SIGNAL VOLTAGE YES
CHANGING?
REPLACE VERTICAL STABILIZER
YES ACTUATOR.
CHECK FOR YAW RATE GYRO SIGNAL AT TEST NO

BOX BETWEEN YAW RATE TEST POINT AND REPLACE YSAS COMPUTER.
TEST BOX GROUND. IS SIGNAL PRESENT?
YES
SHUT OFF ELECTRICAL POWER. CHECK FOR

OPEN WIRES BETWEEN YSAS COMPUTER AND
YAW RATE GYRO WIRE HARNESS. VERIFY GOOD NO
GROUND MODULES AND GROUND TERMINATIONS. YSAS SYSTEM APPEARS TO OPERATE
VERIFY THERE IS NO SHORTED OR CHAFFED CORRECTLY.
WIRES. APPLY ELECTRICAL POWER AND CHECK
FOR RATE GYRO SIGNAL TO TEST BOX TEST
POINT. IS SIGNAL PRESENT?
YES
REPLACE FAULTY YAW RATE GYRO.
G6720172
Page 108
Revision 30 670000
MAINTENANCE MANUAL
FROM SHEET 1
NO SHUT OFF ELECTRICAL POWER. CHECK

CHECK YAW RATE GYRO TEST POINT ON THE NO
FOR OPEN WIRES BETWEEN YSAS REPAIR OPEN WIRES BETWEEN YSAS
YSAS TEST BOX WHILE ROTATING THE YAW RATE COMPUTER AND YAW RATE GYRO. DOES COMPUTER AND YAW RATE GYRO.
GYRO. IS A VOLTAGE CHANGE PRESENT? CONTINUITY EXIST?
YES YES
REPLACE YAW RATE GYRO.
CHECK THE SERVO COMMAND TEST POINT ON NO

THE YSAS TEST BOX WHILE ROTATING THE YAW REPLACE YSAS COMPUTER.
RATE GYRO. IS A VOLTAGE CHANGE PRESENT?
YES
AT THE YSAS TEST BOX, CHECK THE ACTUATOR SHUT OFF ELECTRICAL POWER. CHECK
NO NO REPAIR OPEN WIRES BETWEEN
POSITION TEST POINT TO TEST BOX GROUND FOR OPEN WIRES BETWEEN YSAS
YSAS COMPUTER AND RIGHT
WHILE ROTATING THE YAW RATE GYRO. IS A COMPUTER AND RIGHT VERTICAL
VERTICAL STABILIZER ACTUATOR.
VOLTAGE CHANGE PRESENT? STABILIZER ACTUATOR. DOES CONTINUITY
EXIST?
YES
YES
DISCONNECT THE RIGHT VERTICAL

STABILIZER ACTUATOR PLUG (P4 FOR 500N:
P515 FOR 600N). REAPPLY ELECTRICAL
POWER AND PLACE THE RIGGING SWITCH NO
ON THE YSAS TEST BOX TO THE EXTEND REPLACE YSAS COMPUTER.
POSITION. CHECK THE VOLTAGE AT THE
STABILIZER ACTUATOR PLUG AT
TERMINALS S (H) AND A (L). IS VOLTAGE
GREATER THAN 6 VDC?
YES
REPLACE RIGHT VERTICAL STABILIZER

ACTUATOR.
SHUT OFF ELECTRICAL POWER. CHECK RIGHT

VERTICAL STABILIZER FOR PROPER
INSTALLATION OR DAMAGED CONTROL LINKAGE NO
REPAIR OR REPLACE CONTROL LINKAGE OR
FROM ACTUATOR TO VERTICAL STABILIZER. IS VERTICAL STABILIZER AND VALIDATE THE
STABILIZER PROPERLY INSTALLED AND FREE CONTROL RIGGING AS REQUIRED.
FROM DAMAGE?
YES

ACTUATOR.
G6720173A
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MAINTENANCE MANUAL
FROM SHEET 1
CHECK THE ACCELERATION TEST POINT ON THE NO

YSAS TEST BOX WHILE TILTING THE YSAS REPLACE THE YSAS COMPUTER.
COMPUTER. IS SIGNAL PRESENT?
YES
CHECK THE SERVO COMMAND TEST POINT ON NO

THE YSAS TEST BOX WHILE TILTING THE YSAS REPLACE THE YSAS COMPUTER.
COMPUTER. IS A VOLTAGE CHANGE PRESENT?
YES
AT THE YSAS TEST BOX, CHECK THE ACTUATOR NO SHUT OFF ELECTRICAL POWER. CHECK FOR
POSITION TEST POINT TO TEST BOX GROUND NO REPAIR OPEN WIRES BETWEEN
OPEN WIRES BETWEEN YSAS COMPUTER AND
WHILE TILTING THE YSAS COMPUTER. IS YSAS COMPUTER AND RIGHT
RIGHT VERTICAL STABILIZER ACTUATOR. DOES
VOLTAGE CHANGE PRESENT? VERTICAL STABILIZER ACTUATOR.
CONTINUITY EXIST?
YES YES
DISCONNECT THE RIGHT VERTICAL STABILIZER

ACTUATOR PLUG (P4 FOR 500N: P515 FOR 600N).
REAPPLY ELECTRICAL POWER AND PLACE THE NO
RIGGING SWITCH ON THE YSAS TEST BOX TO REPLACE THE YSAS COMPUTER.
THE EXTEND POSITION. CHECK THE VOLTAGE
AT THE STABILIZER ACTUATOR PLUG AT
TERMINALS S (H) AND A (L). IS VOLTAGE
GREATER THAN 6 VDC?
YES

ACTUATOR.
SHUT OFF ELECTRICAL POWER. CHECK RIGHT

VERTICAL STABILIZER FOR PROPER
INSTALLATION OR DAMAGED CONTROL LINKAGE NO
REPAIR OR REPLACE CONTROL LINKAGE OR
FROM ACTUATOR TO VERTICAL STABILIZER. IS VERTICAL STABILIZER AND VALIDATE THE
STABILIZER PROPERLY INSTALLED AND FREE CONTROL RIGGING AS REQUIRED.
FROM DAMAGE?
YES

ACTUATOR.
G6720174A
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MAINTENANCE MANUAL
ACCEL ACTUATOR
POSITION
EXTEND
OFF
YAW SERVO RETRACT

RATE COMMAND
15 +15 GROUND
VDC VDC
G672018
Figure 103. YSAS Ground Test Box
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670000 Revision 30
MAINTENANCE MANUAL
Page 112
Revision 43 670000
MAINTENANCE MANUAL
Section
671000
Main Rotor Flight
Controls (369D/E/FF
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR FLIGHT CONTROLS

1. Main Rotor Flight Controls provides inboard support for the collective
torque tube.
Main rotor flight controls consist of scissors,
rotating swashplate, stationary swashplate, C. Collective Controls
mixer controls (lateral bellcrank, longitudinal
idler, collective pitch mixer bellcrank, longitu- Pilots compartment collective controls consist
dinal bellcrank, longitudinal controlmixer of collective pitch stick, collective bungee, and
link, longitudinal link, and two mixer links) the interconnecting shaft and linkage. All
and five pitch control rods. components, except the stick and tunnel
routed collective mixer control rod, are located
Movement of collective pitch cyclic control within the pilots seat structure. Dual control
sticks is transferred to mixer controls through provisions are incorporated into the pilots
control rods routed up through the controls compartment collective controls installation.
tunnel at the center of Sta. 78.50 bulkhead.
Mixer controls transfer required combination D. Pilots Collective Pitch Stick
of collective, longitudinal and lateral travel
through swashplates to main rotor blades. The The pilots collective pitch stick consists
helicopter may be equipped with either primarily of a switch housing, throttle grip and
righthand or lefthand control configurations friction mechanism, collective stick tube and
consisting of cyclic, collective and antitorque friction mechanism and gas producer control
controls. The main rotor hub and blades, shaft with right angle (pinion and bevel gear)
swashplate and control linkage to the crew drive. Collective pitch stick controls include:
compartment controls are identical on either the N1 throttle and idle stop release ring, N2
basic configuration. governor trim switch, landing light switch,
stick friction adjustment grip throttle friction
NOTE: This section contains information for nut and a starterignition switch.
both L/H command and R/H command heli-
copters. Unless otherwise denoted, the in- E. Copilots Collective Pitch Stick
formation in this section pertains to both
type helicopters. The copilots collective stick consists primarily
of a switch housing, N1 throttle grip, stick
tube, and internal gas producer control shafts
A. Collective Mixer, Lateral and Longitudinal
having right angle (pinion and bevel) gear
Mixer (TunnelRouted) Control Rods
drive. The gear drive linkage is essentially the
same as in pilots collective stick housing.
Tunnelrouted control rods mechanically Copilots collective controls include an N2
transfer displacement of flight controls to governor trim switch.
associated bellcranks and the idler at the front
of main rotor mast base. All tunnelrouted F. Collective Pitch Stick Friction
control rods are removed, inspected, repaired
and installed in same manner. Pilots collective pitch stick friction allows the
pilot to vary amount of effort required to raise
B. Controls Support Bracket and Bellcranks and lower the collective pitch stick as well as
increasing stick resistance to position change
The controls support bracket is below the resulting from sudden changes in main rotor
pilots seat cover, between right and left collective forces. The grip is marked with
inboard sides of the seat structure. The arrows indicating direction of rotation for
bracket provides the hingeline for longitudinal increasing or decreasing friction. Friction can
and lateral idler bellcrank, tail rotor bellcrank, be applied or released with one hand by
and the engine droop control bellcrank. It also rotating the friction adjustment grip.
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671000 Revision 21
MAINTENANCE MANUAL
Collective stick friction mecha- bracket attachment is to counteract these

CAUTION nism is designed so that stick forces so that collective stick loads are
cannot be locked in maximum friction point. relatively constant throughout full range of
Safety of flight considerations require that travel. There are two adjustments provided to
pilot be able to instantly change any estab- establish or correct collective flight loads. The
lished collective pitch stick position, without collective bungee spring corrects variation in
changing friction adjustment in event of a collective load from low pitch (level flight) to
power failure. There is no suitable check high pitch (climb). Setting of overcenter bolt to
that pilot can make, with helicopter on the raise or lower bungee fitting reduces or
ground, to determine if maintenance adjust- increases overall collective forces in both low
ment of collective friction is correct. This is pitch (level flight) and high pitch (climb).
due to large force application necessary to
override collective bungee and blades rest- I. Inboard Collective Stick Socket Assembly
ing on droop stops. If stick friction is inade- Inboard collective stick socket assembly is a
quate during flight, a maintenance check cast magnesium housing that contains gas
should be performed. Once friction adjust- producer linkage and provisions for attach-
ment is determined to be correct at low fric- ment of dual collective controls. Internal gas
tion point, any further mechanical adjust- producer drive gear linkage is essentially the
ment to alter (increase) friction at low point same as that in the pilots collective stick
can cause stripping of mechanism when grip housing with the addition of a splined N1
is fully rotated for maximum friction. pinion gear for simplified installation or
G. Collective Control Interconnecting removal of a copilots collective stick. The lower
Torque Tube end of the collective mixer (tunnelrouted)
control rod is attached to the socket housing
The collective interconnecting torque tube and the exterior bellcrank, idler and link
consists of the tube, bungee bracket, bungee transfer movement of the pilots collective stick
fitting and a tube support bearing. The torque throttle to the gas producer controls routed
tube interconnects the pilots collective pitch through the fuselage to the engine.
stick and the inboard collective stick socket
J. Cyclic Controls
assembly. The torque tube is supported at the
left end by a bearing installed in seat struc- The cyclic pitch control system is a fully
ture, and at the right end by the controls mechanical control system. Any combination of
support bracket. lateral and longitudinal cyclic pitch stick
movement is mixed by cyclic lateral and
H. Collective Bungee longitudinal control mixers and transferred to
The collective bungee installation consists of a the main rotor swashplate, which applies the
male bearing assembly, female bearing combined motion through pitch control rods to
assembly, spring and retainer. This unit the main rotor blades. Forward and rearward
attaches between the bungee overcenter movement of the cyclic pitch stick causes
fitting and bungee bracket of collective helicopter motion in a longitudinal direction,
interconnecting torque tube. The collective while sidetoside movement provides motion
bungee helps maintain selected collective pitch in a lateral direction. This action varies lift
stick position in flight by counteracting forces developed by main rotor blades and serves as
that are fed back in collective pitch stick(s) primary control by horizontal flight. Pilots
(blade pitching moments, rotor head strap compartment cyclic controls include the control
pack torsion when collective pitch stick is stick, a lateral interconnecting rod, lateral
raised or lowered from midposition, and cyclic bellcrank, longitudinal cyclic control
combined imbalance of forces in the controls interconnecting torque tube and lateral and
system). Flight characteristics of the helicopter longitudinal friction mechanism.
are such that collective forces are relatively K. Pilots Cyclic Control Stick
low during most stick travel from low to high
blade pitch. At a point near full pitch, stick The pilots cyclic control stick consists of a grip
forces reverse and become heavy. The purpose and a tube riveted in a socket. The cyclic grip
of the adjustable bungee and the overcenter contains a toggle switch for cyclic trim control
Page 2
Revision 21 671000
MAINTENANCE MANUAL
and a trigger switch for radio/interphone should the check valve spring fail, the one
communication. A blank switch socket is way lock does not function to shunt longitudi-
provided at the left of the trim switch for nal feedback forces to structure. The unit is
optional equipment. Coiled, insulated and mounted in two pivoting supports attached to
openended wiring is provided in the grip for seat structure, and has a transparent, vented
connection to an optional switch. reservoir with a capacity of approximately 0.67
fluid ounce (20 cc). The oneway lock control
L. Copilots Cyclic Control Stick system is serviced through the filler with
hydraulic oil (6, Table 203).
The copilots cyclic control stick is similar to
the pilots except electrical wiring exits above O. Cyclic Trim Actuators
the stick socket. The copilots cyclic stick is
detachable and may be removed or installed by Each of the two cyclic trim actuators consists
use of two quickrelease pins. of an actuator, housing support, trim tube and
spring assembly. The actuator is essentially a
M. Pilots Compartment Lateral and motordriven, variable length shaft that
Longitudinal Cyclic Control Linkage compresses a spring assembly, counteracting
feedback forces from the main rotor and
Pilots compartment lateral and longitudinal compensating for imbalance conditions such as
cyclic control linkage consists of two control those imposed by crosswinds or unevenly
rods and a bellcrank that interconnect lateral distributed cargo. Cyclic trim is controlled by
control movement, and the cyclic torque tube the cyclic trim switch on top of cyclic stick grip.
and oneway lock control system that inter- The cyclic trim switch has five positions:
connect longitudinal control movement of normally OFF at the center, and momentary
pilots cyclic stick to tunnelrouted mixer FORWARD, AFT, LEFT, and RIGHT. When
control rods. R/H command configuration is the trim switch is moved off center to any of
identical to L/H command except for an the four trim positions, one of the trim motors
additional lateral control rod that attaches operates to provide trim spring force in the
lower end of copilots cyclic control stick to desired direction. By momentarily activation of
lateral cyclic bellcrank. the switch, very small trim increments are
obtained. Trim forces cannot be applied in two
N. OneWay Lock Control System directions simultaneously; when both lateral
and longitudinal trim corrections are required,
The oneway lock of the cyclic control system it is necessary to apply first one, then the
is located in longitudinal control linkage other. Travel of the cyclic pitch control stick is
within the pilots seat structure. The oneway not limited by the cyclic trim mechanism; trim
lock control system is essentially a selfcon- spring tension can be overridden at any time.
tained, closedloop hydraulic unit consisting
of a check valve, relief valve and pushrod P. RoofMounted Control Rods (600N)
mechanism. The check valve is seated when
longitudinal control force (feedback) origi- The roofmounted control rods transmit cyclic
nated by main rotor tends to move the and collective flight control input from the
oneway lock (and cyclic stick) in an aft tunnelrouted control rods, via the forward
direction. Seating the check valve prevents roofmounted bellcranks, to the link assem-
unwanted aft movement of cyclic stick and blies, via the aft roofmounted bellcranks, at
shunts feedback force to helicopter structure. the mixer assembly.
Normally, only very slight aft movement of the
cyclic stick is required to unseat the check Q. RoofMounted Bellcranks (600N)
valve. Should the check valve (or pushrod
shaft that unseats the valve) gall and freeze in The forward roofmounted bellcrank transfer
the valveclosed position, a force of approxi- controls input from the tunnelrouted control
mately 30 pounds is necessary to open the rods to the roofmounted control rods. The aft
relief valve and bypass the check valve. This roofmounted control rods transfer controls
force is then required for each subsequent aft input from the roofrouted control rods to the
movement of the cyclic stick. Conversely, link assemblies.
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671000 Revision 21
MAINTENANCE MANUAL
1. MAIN ROTOR DRIVE SHAFT

2. DAMPER
3. BLADE ATTACH PIN 1
4. MAIN ROTOR BLADE
5. ROTOR MAST SUPPORT
6. ROTATING SWASHPLATE
7. MAIN ROTOR CONTROLS (MIXER, IDLER
BELLCRANKS AND LINKS)
8. LATERAL MIXER CONTROL ROD (CYCLIC)
9. LONGITUDINAL MIXER CONTROL ROD (CYCLIC)
10. COLLECTIVE MIXER CONTROL ROD
11. STATIONARY SWASHPLATE
3
2
4
11
10
7 7
5
9
6
8 12. COLLECTIVE CONTROL TORQUE TUBE

25 13. COPILOTS COLLECTIVE PITCH STICK
14. DROOP CONTROL OVERRIDE LINK
27 15. COPILOTS CYCLIC STICK
16. LATERAL CYCLIC FRICTION KNOB
23 17. CYCLIC LATERAL CONTROL ROD
24 18. LATERAL CYCLIC TRIM ACTUATOR
26 19. LONGITUDINAL CYCLIC TRIM ACTUATOR
20. LONGITUDINAL CYCLIC FRICTION KNOB
21. ONEWAY LOCK
22. CYCLIC CONTROL TORQUE TUBE
22 23. GAS PRODUCER CONTROL ROD
24. COLLECTIVE CONTROL BUNGEE
25. ANTITORQUE CONTROL ROD (REF)
26. PILOTS COLLECTIVE PITCH STICK
12 27. PILOTS CYCLIC STICK
14
15
21 20
19
17 13
16
18
G670000A
Figure 1. Main Rotor and Control System (369D/E/FF 500N)
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Revision 21 671000
MAINTENANCE MANUAL
1. MAIN ROTOR DRIVE SHAFT

2. DAMPER
3. BLADE ATTACH PIN 4
4. MAIN ROTOR BLADE
5. ROTATING SWASHPLATE 2 1
6. MAIN ROTOR CONTROLS (MIXER, IDLER
BELLCRANKS AND LINKS)
7. LATERAL MIXER CONTROL ROD (CYCLIC)
8. LONGITUDINAL MIXER CONTROL ROD (CYCLIC)
9. COLLECTIVE MIXER CONTROL ROD
10. COLLECTIVE CONTROL TORQUE TUBE
11. COPILOTS COLLECTIVE PITCH STICK
3
12. COPILOTS CYCLIC STICK
13. LATERAL CYCLIC FRICTION KNOB
14. CYCLIC LATERAL CONTROL ROD
15. LATERAL CYCLIC TRIM ACTUATOR
16. LONGITUDINAL CYCLIC TRIM ACTUATOR
17. LONGITUDINAL CYCLIC FRICTION KNOB
18. ONEWAY LOCK
19. CYCLIC CONTROL TORQUE TUBE
20. GAS PRODUCER CONTROL ROD
21. COLLECTIVE CONTROL BUNGEE
22. ANTITORQUE CONTROL ROD (REF)
23. PILOTS COLLECTIVE PITCH STICK
24. PILOTS CYCLIC STICK
5
9
6
8
22
21 7
12
20
24
19
18 23
10
11
17
16 14
13
15
6G67035A
Figure 2. Main Rotor and Control System (600N)
Page 5/(6 blank)

671000 Revision 21
MAINTENANCE MANUAL

1. TunnelRouted Control Rod Replacement tube to angle up through the double
hole.
(Ref. Figure 401)
(9). Remove bolt from bottom of 7012 tube
A. TunnelRouted Control Rod Removal and lower to belly of aircraft and angle
up through the double hole.
Special Tools (10). Remove bolts from bottom of 7007 tube
(Ref. Section 910000) and lower to the belly of aircraft, then
Item Nomenclature angle up through the double hole.
(11). Move 7009 tube to the other side of
center beam and angle up through the
Before disconnecting collec- double hole.
WARNING tive pitch control rod, install
collective bungee installation tool to B. TunnelRouted Control Rod Installation
prevent spring reaction due to droop
stop load on control rod. To reinstall tunnelrouted control rods,
reverse the sequence of TunnelRouted
(1). Install collective bungee installation Control Rod Removal.
tool (ST508) and remove collective
bungee. 2. RoofMounted Control Rod Replacement
(600N)
(2). For access to lower rod ends, remove
controls access door at base of canted (Ref. Figure 402)
bulkhead in cargo compartment. A. RoofMounted Control Rod Removal
(3). Hand turn main rotor blades to align (600N)
blue blade to right side of aircraft.
Special Tools
(4). Disconnect upper end of control rod. (Ref. Section 910000)
Item Nomenclature
(5). Remove double boot from control tunnel
cover. All tubes will be removed ST508 Collective bungee installation tool
through the double hole.
(1). Install collective bungee installation
Use care during removal of con-
CAUTION trol rods. Any surface damage
bungee.
caused by hasty removal may result in un-
serviceable control rods. (2). For access to roofmounted control
rods, remove upper fuselage controls
(6). Move blue blade pitch housing down as fairing.
far as it will go. This will allow the
tubes to go past the housing. NOTE: If same rods are to be reinstalled, mark
rods for proper positioning upon reinstalla-
(7). Remove bolts from bottom of 369A7009 tion. If new rods are installed, main rotor
and 7011 tubes. flight controls must be rerigged.
(8). Move cyclic controls so that the 7012 (3). Mark control rod for proper reinstalla-
tube moves to its highest point. Place tion.
7009 tube to the far right and lower out
of way. Lower 7011 tube to the left side (4). Remove hardware from control rods
of center beam. This will allow 7011 and remove rods from aircraft.
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671000 Revision 21
MAINTENANCE MANUAL
DOUBLE BOOT
369A7009
369A7007 DOUBLE BOOT
369A7011 HOLE
369A7012
369A7012
369A7011
369A7007
369A7009
VIEW LOOKING FORWARD VIEW LOOKING FORWARD

VIEW A VIEW B
DOUBLE BOOT 369A7007 DOUBLE BOOT

HOLE HOLE
369A7012
369A7007
369A7009 369A7009

VIEW LOOKING FORWARD VIEW D
VIEW C
DOUBLE BOOT
HOLE
369A7009

VIEW E
G671001
Figure 401. TunnelRouted Control Rod Installation
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MAINTENANCE MANUAL
LINK ASSEMBLY
AFT ROOFMOUNTED
BELLCRANKS
ROOFMOUNTED
CONTROL RODS
FORWARD
ROOFMOUNTED
BELLCRANKS ROTATING
SWASHPLATE
MAIN ROTOR CONTROLS

COLLECTIVE MIXER (MIXER, IDLER BELLCRANKS
CONTROL ROD AND LINKS)
DIRECTIONAL
LONGITUDINAL MIXER CONTROL ROD
CONTROL ROD
(CYCLIC) LATERAL MIXER
CONTROL ROD
(CYCLIC)
6G67039
Figure 402. RoofMounted Controls Installation

B. RoofMounted Control Rod Installation 3. RoofMounted Bellcrank Replacement
(600N) (600N)
(Ref. Figure 402) Replacement of the roof
(1). Install control rods in bellcranks mounted bellcranks is the same procedure for
ensuring RH threaded rod end is the forward and aft bellcranks.
forward.
A. RoofMounted Bellcrank Removal (600N)
(2). Install hardware connecting control
rods. Torque nuts to 30 40 inch Special Tools
pounds (3.39 4.52 Nm) and install (Ref. Section 910000)
cotter pin. Item Nomenclature
(3). Remove collective bungee installation
tool. (1). Install collective bungee installation
(4). Reinstall upper fuselage controls bungee.
fairing.
(2). For access to roofmounted control rods
and bellcranks, remove upper fuselage
(5). Perform flight controls rigging check. controls fairing.
Page 403
671000 Revision 21
MAINTENANCE MANUAL
(3). Remove hardware connecting rod from (2). Ensure bushing protrudes a minimum
bellcrank. of 0.010 inch (0.254 mm) to a maximum
of 0.060 inch (1.524 mm) beyond the
(4). Remove hardware from bellcrank pivot surface of mixer.
point and remove bellcrank.
B. RoofMounted Bellcrank Installation (3). Torque nuts to 30 40 inchpounds
(600N) (3.39 4.52 Nm) and install cotter pin.
NOTE: Ensure bellcranks are installed in prop- (4). Remove collective bungee installation
er position. If bellcranks are install in the tool.
wrong position, rigging will be impossible
(Ref. Illustrated Parts Catalog). (5). Reinstall upper fuselage controls
fairing.
(1). Install bellcrank in mount with word
FORWARD facing up and arrow 5. Controls Support Bracket and Bellcrank
pointing towards front of aircraft. Replacement
(2). Install hardware connecting bellcrank
(Ref. Figure 403)
to mount. Torque nuts to 30 40
inchpounds (3.39 4.52 Nm) and A. Controls Support Bracket and Bellcrank
install cotter pin. Removal
(3). Reinstall disconnected control rods.
(4). Remove collective bungee installation Special Tools
tool. (Ref. Section 910000)
Item Nomenclature
(5). Reinstall upper fuselage controls ST508 Collective bungee installation tool
fairing.
4. Link Assembly Replacement (600N)
(1). Remove foot fairings and controls
(Ref. Figure 402) access door (Sta. 78.50) and pilots seat
cover.
A. Link Assembly Removal (600N)
Before disconnecting collec-
WARNING tive pitch control rod, install
Special Tools
(Ref. Section 910000) collective bungee installation tool to
Item Nomenclature prevent spring reaction due to droop
stop load on control rod.
(1). Install collective bungee installation tool (ST508) and remove collective
tool (ST508) and remove collective bungee.
bungee.
(3). Disconnect tunnelrouted control rods.
(2). Remove upper fuselage controls fairing.
(4). Disconnect upper end of each cyclic
NOTE: Upper link bolt has a bushing in the trim actuator.
mixer bellcrank.
(5). Disconnect floorrouted tail rotor
(3). Remove hardware from link and
control rod from tail rotor bellcrank.
remove link from aircraft.
B. Link Assembly Installation (600N) (6). Disconnect Sta. 70 lateral control rod
from lateral idler bellcrank.
(1). Install link between lower bellcrank
and mixer bellcrank with hardware (7). Disconnect oneway lock from longitu-
previously removed. dinal idler bellcrank.
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MAINTENANCE MANUAL
COLLECTIVE TORQUE
BUNGEE SUPPORT BRACKET TUBE
WASHER (SPECIAL)
* *
* * CONTROLS SUPPORT
BRACKET
DROOP CONTROL
OVERRIDE LINK
*
(COUNTERSUNK)
* * TAIL ROTOR BELLCRANK
BEARING
BUSHING BEARING
NOTE 2 (NOTE 3)
LATERAL IDLER
BELLCRANK
* FLOORROUTED TAIL
BEARING 3/16 IN.
ROTOR CONTROL ROD
AND SPACER (4.7625 MM)
* DIAMETER
*
BUSHING * *
(NOTE 3)
1/4 IN.
(6.35 MM) BEARING
DIA STA 70 LATERAL
CONTROL ROD
*
(COUNTERSUNK)
BEARING
SPACER
* * LONGITUDINAL
NOTE 6
IDLER BELLCRANK
LATERAL CYCLIC STA. 72 DROOP
ONEWAY TRIM ACTUATOR CONTROL BELLCRANK
LOCK
LONGITUDINAL CYCLIC *
TRIM ACTUATOR *
NOTE 4
NOTE 6
BOLT INSTALLATION
HOLE
2. SHIM WASHERS USED AS REQUIRED TO OBTAIN NO SIDELOAD

ON ONEWAY LOCK.
* 3. BUSHING AND BOLT MUST NOT ROTATE WITH TRIM UNIT
AFTER INSTALLATION.
4. BOND JUMPER ATTACHMENT TYPICAL FOR BOTH ACTUATORS.
NOTES: 5. DOUBLE ASTERISK (**) INDICATES PARTS THAT MAY BE EITHER
1. ASTERISK (*) IDENTIFIES SLOTTED BUSHINGS. EDGE OF BUSHINGS MAGNESIUM OR ALUMINUM ALLOY.
MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO A MAXIMUM 6. REPLACEMENT PARTS HAVE NUTPLATE RIVETED IN PLACE.
OF 0.080 IN. (2.032 MM) ABOVE OUTSIDE SURFACE OF PART AFTER WASHER, NUT AND COTTER PIN NOT REQUIRED. G671002A
NUT IS TIGHTENED.
Figure 403. Controls Support Bracket, Idler Bellcranks and Cyclic Trim Actuators Installation
Page 405
671000 Revision 21
MAINTENANCE MANUAL
(8). Remove pilots collective pitch stick. (8). Connect floorrouted tail rotor control
rod to tail rotor bellcrank.
(9). Provide support for collective torque
tube. Remove bolts, washers and nuts (9). Connect upper end of each cyclic trim
securing bungee support bracket and actuator.
collective torque tube to controls
support bracket. NOTE: Lateral actuator uses 3/16 inch (4.7625
mm) diameter bolt. The longitudinal actua-
(10). Disconnect aft end of droop control tor requires 1/4 inch (6.035 mm) diameter
override link from collective torque tube bolt.
bracket.
(10). Connect lower ends of tunnelrouted
(11). Remove Sta. 72 droop control bellcrank control rods.
from support bracket.
(12). Disconnect and remove support bracket (11). Install collective bungee and remove
from seat structure. Avoid striking any collective bungee installation tool.
bellcranks and pushrods.
6. Pilots Collective Pitch Stick Replacement
B. Controls Support Bracket and Bellcrank (L/H Command)
Installation
(Ref. Figure 404)
(1). Carefully position assembled support
bracket and bellcranks between seat A. Pilots Collective Pitch Stick Removal
structure bulkheads and secure with (L/H Command)
attaching hardware.
(2). Position Sta. 72 droop control bellcrank Special Tools
in support bracket and install. (Ref. Section 910000)
Item Nomenclature
NOTE: Cap is matched to cradle of each control ST508 Collective bungee installation tool
support bracket. Check that numbers on
each part are identical before accomplishing
step (3). below. (1). Remove outboard collective stick cover.
(3). Check that two slotted bushings are in (2). Disconnect pilots collective stick
place in bungee support bracket. electrical plug.
Position collective torque tube and
bungee bracket on support bracket (3). Remove attaching hardware that
cradle and install cradle bolts, washers secures guide to seat structure bracket.
and nuts. Ensure index groove, in edge
of cap that clamps torque tube to Before disconnecting collec-
support bracket cradle, mates with WARNING tive stick, install collective
matching index at bracket cradle bungee installation tool to prevent
parting surface. spring reaction due to droop stop load
on controls.
(4). Install pilots collective pitch stick.
(5). Connect aft end of droop control tool (ST508).
override link to collective torque tube
droop control bracket. (5). Remove collective bungee and inboard
collective socket. Disconnect droop
(6). Connect oneway lock to longitudinal
control override link (369D/E/FF
idler bellcrank.
500N only), slide bungee bracket to
NOTE: For following steps, ensure that slotted side, remove cradle cap and slide
bushing is in bellcrank ear. collective torque tube inboard.
(7). Connect Sta. 70 lateral control rod to (6). Remove attaching hardware that
lateral idler bellcrank. connects stick housing to torque tube.
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MAINTENANCE MANUAL
COLLECTIVE MIXER
TUNNELROUTED
CONTROL ROD
NOTE 3
INBOARD COLLECTIVE
STICK SOCKET
BUNGEE OVERCENTER
GAS PRODUCER ADJUSTMENT BOLT
CONTROL ROD (NOTE 1)
BUNGEE
GAS PRODUCER
INTERCONNECTING
TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
BUNGEE SPRING N2 DROOP CONTROL OVERRIDE

ADJUSTMENT NUT LINK (369D/E/FF 500N)
(NOTE 2 SEE CAUTION)
COLLECTIVE STICK FRICTION
MECHANISM AND GUARD
THROTTLE
PILOTS COLLECTIVE
PITCH STICK
NOTE 4
THROTTLE NOTE 5
FRICTION SLEEVE GUIDE FUSELAGE
BUSHING
SKIN
NOTE 5
NOTES:
1. ROTATED CLOCKWISE TO INCREASE, COUNTERCLOCKWISE TO
DECREASE OVERALL COLLECTIVE DOWNLOADS.
2. ROTATED CLOCKWISE TO INCREASE COUNTERCLOCKWISE TO
DECREASE, BUNGEE PRELOAD.
CAUTION: DO NOT ADJUST BUNGEE SPRING TENSION WHILE BUNGEE
INSTALLATION TOOL IS INSTALLED. USE OVERCENTER ACTION OF STICK
TO COMPRESS SPRING TO REMOVE TOOL.
3. BUSHINGS MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO
A MAXIMUM OF 0.060 IN. (1.524 MM) AFTER BOLT IS TIGHTENED.
4. FOUR NUTS TORQUED EQUALLY AND BY SMALL INCREMENTS. G671003B
5. WASHERS ARRANGED TO ALIGN GUIDE WITH STICK; LOOSELY
SPACED WITH THREE WASHERS.
Figure 404. Dual Collective Controls (L/H Command)
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671000 Revision 21
MAINTENANCE MANUAL
(7). Remove stick by sliding it outboard off (1). Remove stick cover from seat structure.
torque tube.
B. Pilots Collective Pitch Stick Installation (2). Disconnect pilots collective stick
(L/H Command) electrical plug.
Consumable Materials (3). Remove attaching hardware that

(Ref. Section 910000) secures guide to seat structure bracket.
Item Nomenclature
CM116 Grease, aircraft and instrument Before disconnecting collec-
WARNING tive stick, install collective
bungee installation tool to prevent
(1). Lubricate stick housing socket with spring reaction due to droop stop load
grease (CM116). on controls.
(2). Install stick by sliding housing on
collective control interconnecting torque (4). Install collective bungee installation
tube. Install bolts, washers and nuts. tool (ST508).
Tighten nuts equally and by small
increments until correct torque is (5). Remove collective bungee and inboard
applied. collective socket. Disconnect droop
(3). Connect electrical plug. control override link (369D/E/FF
500N only), slide bungee bracket to
(4). Install outboard collective stick cover. side, remove cradle cap and slide
Raise and lower stick; verify that collective torque tube inboard.
wiring does not foul.
(5). Remove snap plug from exterior skin, (6). Disconnect gas producer control rod.
rotate throttle and visually check for
zero backlash between gas producer (7). Remove attaching hardware that
interconnect torque tube and hexagonal connects stick housing to torque tube.
interior surfaces of drive gearshaft in
stick housing. Eliminate any backlash B. Pilots Collective Pitch Stick Installation
by tightening pipe plug in end of torque (R/H Command)
tube; zero backlash is required at both
ends of tube.
(6). Check that inboard stick socket gears Consumable Materials
are at midtravel when pilots stick (Ref. Section 910000)
throttle grip is set to midtravel. If not, Item Nomenclature
adjust collective stick gas producer CM116 Grease, aircraft and instrument
control linkage.
7. Pilots Collective Pitch Stick Replacement
(R/H Command) (1). Lubricate surfaces that are in contact
during rotation with grease (CM116).
(Ref. Figure 405)
A. Pilots Collective Pitch Stick Removal (2). Ensure that pilots and copilots throttle
(R/H Command) grips are in same relative positions.
Slide pilots stick housing on collective
interconnecting torque tube, align
Special Tools matching holes and secure stick to
(Ref. Section 910000) torque tube. Connect gas producer
Item Nomenclature control rod. Align and/or match bell-
ST508 Collective bungee installation tool crank centerline, gearshaft assembly
gear cutout and pilots throttle.
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PILOTS COLLECTIVE
COLLECTIVE PITCH STICK COVER
FRICTION GUIDE
FLEXIBLE
CLOSURE
PILOTS THROTTLE
THROTTLE FRICTION
GRIP NUT GAS PRODUCER INTERCONNECTING
TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
IDLE STOP COLLECTIVE

RELEASE RING STICK FRICTION
CONTROL N2 DROOP CONTROL
OVERRIDE LINK
PILOTS COLLECTIVE
(369D/E/FF 500N)
PITCH CONTROL STICK
COPILOTS COPILOTS NOTE 3

THROTTLE COLLECTIVE PITCH
GRIP CONTROL STICK
PLAIN
BUSHING
NOTE 1
NOTE 1
SLOTTED
BUSHING
(NOTE 2)
BUSHING INSTALLATION
NOTES:
1. ARRANGE WASHERS TO LINE UP GUIDE WITH STICK; SPACE LOOSELY WITH
THREE WASHERS.
2. SLOTTED BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH (0.254 MM) TO A
MAXIMUM OF 0.060 INCH (1.524 MM) AFTER BOLT IS TIGHTENED.
3. FOUR NUTS TORQUED; EQUALLY AND BY SMALL INCREMENTS.
4. ALLOWABLE FREE PLAY IN COPILOTS TWIST GRIP IS 5.
G671004A
Figure 405. Dual Collective Controls (R/H Command)
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MAINTENANCE MANUAL
(3). Position friction guide in seat structure (3). Remove hardware from stick tube
bracket with plain bushing, slotted socket adapter and remove pitch stick
bushing, and three washers loosely assembly by sliding it forward and off
spaced between bracket ears so guide is the inboard stick housing.
in line (parallel) with stick. Install bolt,
two washers, nut and new cotter pin. B. Copilots Collective Pitch Stick
Installation (L/H Command)
(4). Connect electrical plug.
(5). Perform operational check of collective (Ref. Section 910000)
stick friction and adjust friction Item Nomenclature
mechanism as necessary.
(6). Install collective stick cover on seat
structure. Check that wiring is not
(1). Lubricate stick housing socket with
fouled when stick is raised and lowered.
grease (CM116).
8. Copilots Collective Pitch Stick (2). Rotate pilots or copilots throttle grips
Replacement (L/H Command) so that the grip attach bolts are down.
(Ref. Figure 406) (3). Install copilots stick socket adapter on
the inboard housing socket extension
A. Copilots Collective Pitch Stick Removal and, while moving copilots throttle
(L/H Command) back and forth slightly to get engage-
ment of the socket pinion and adapter
(1). Remove collective stick cover from seat splines, slide the adapter into place.
structure.
(4). Install attaching hardware to secure
(2). Disconnect electrical plug. socket adapter.
STICK ASSEMBLY
COLLECTIVE PITCH STICK ASSEMBLY

NOTE 2
0.0300.150 IN.
NOTES: (0.7623.81 MM)
1. 0.0300.150 IN. (0.7623.81 MM) MUST BE MAINTAINED BETWEEN (NOTE 1)
STOP AND BRACKET WHEN PILOT COLLECTIVE CONTROL IS IN
FULL DOWN POSITION. DOWNSTOP CLEARANCE
G671005A
2 LUBE SOCKET WITH GREASE BEFORE STICK INSTALLATION
Figure 406. CoPilots Collective Stick Assembly Installation (L/H Command)
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Revision 21 671000
MAINTENANCE MANUAL
(5). Connect electrical plug. backlash is required at both ends of

tube.
(6). Position downstop assembly. Check that
0.0300.150 inch (0.7623.302 mm) NOTE: The R/H command configuration collec-
clearance exists between downstop and tive friction mechanism is the same as L/H
seat structure with collective pitch stick command except no separate friction guard
in full down position. is provided, since the pilots collective pitch
cover also functions as a guard for the fric-
(7). Install collective cover on seat struc- tion mechanism.
ture. Check that wiring is not fouled
when stick is raised and lowered. 10. Collective Control Interconnecting Torque
Tube Replacement
9. Copilots Collective Pitch Stick
Replacement (R/H Command) (Ref. Figure 407)
A. Collective Control Interconnecting
(Ref. Figure 404) Torque Tube Removal
A. Copilots Collective Pitch Stick Removal
(R/H Command) Special Tools
Remove copilots collective stick according to Item Nomenclature
instructions in Pilots Collective Pitch Stick
Removal (L/H Command) except disregard
information on friction guide.
B. Copilots Collective Pitch Stick WARNING tive pitch control rod, install
Installation (R/H Command) collective bungee installation tool to
Consumable Materials stop load on control rod.
Item Nomenclature
CM116 Grease, aircraft and instrument bungee.
(2). Remove inboard collective socket
(1). Lubricate stick housing socket with assembly.
grease (CM116).
(3). Disconnect aft end of droop control
(2). Slide stick housing on collective control override link (369D/E/FF 500N only)
interconnecting torque tube. Align from torque tube droop control bracket.
matching holes and install bushings,
bolts, washers and nuts. Tighten (4). Remove hardware securing bungee
equally and by small increments until support bracket reinforcement strap
proper torque is applied. and torque tube to controls support
bracket. Slide bungee bracket aside and
(3). Install outboard collective stick cover. remove controls bracket cradle cap and
Secure electrical plug and check that reinforcement strap.
wiring will not foul when stick is raised
(5). Slide collective control torque tube
and lowered.
sufficiently toward right side of seat
(4). Remove snap plug from exterior skin, structure to remove pilots collective
rotate throttle and visually check for pitch stick housing from end of tube.
zero backlash between gas producer (6). Remove hardware that connects stick
interconnect tube and hexagonal ID of housing to torque tube.
drive gearshaft in stick housing.
Eliminate any backlash by tightening (7). Remove stick by sliding it outboard and
pipe plug in end of torque tube; zero off torque tube.
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MAINTENANCE MANUAL
(8). Remove torque tube by sliding it Position torque tube, controls bracket
approximately three inches toward cradle cap, reinforcement strap and
right side of seat structure to disengage bungee bracket on controls support
left end from support bearing inside left bracket. Check that captocradle
torque tube support. Provide support at index grooves are matched. Install with
seat structure lightening hole and care, hardware removed. Apply thin layer of
fully withdraw torque tube from grease (CM116) to sliding surfaces of
structure. bungee overcenter fitting.
(9). Remove gas producer interconnect (7). Install droop control override link
torque tube by carefully sliding it out of (369D/E/FF 500N only) to torque tube
collective torque tube. droop control bracket.
B. Collective Control Interconnecting (8). Install inboard collective socket

Torque Tube Installation assembly.
(9). Complete installation of pilots collec-

tive stick.
Item Nomenclature
(10). Install collective bungee.
11. Collective Bungee Replacement
(1). Install gas producer interconnect
torque tube by sliding it carefully into (Ref. Figure 407)
place in collective control interconnect-
ing torque tube. A. Collective Bungee and OverCenter
Fitting Removal
(2). Insert torque tube into lightening hole
in seat structure. Use care when Special Tools
inserting tube into place to prevent (Ref. Section 910000)
scraping on edge of hole. Insert tube Item Nomenclature
only to a position that provides suffi-
cient space between tube end and ST508 Collective bungee installation tool
fuselage skin for installation of pilots
stick housing on end of tube.
(3). Lubricate pilots stick housing with WARNING tive pitch control rod, install
grease (CM116). collective bungee installation tool to
(4). Slide pilots stick housing on collective stop load on control rod.
control interconnecting torque tube.
(1). Remove pilots seat cover from seat
NOTE: Stick housing must be placed on torque structure.
tube before installing torque tube attaching
hardware. (2). Raise collective stick and use torque
tube overcenter action to compress
(5). Complete insertion of tube and position bungee spring until bungee installation
left end of tube in fixed bearing bore. tool (ST508) fits over spring retainers.
Rotate torque tube slowly back and Secure tool halves in place with clamp.
forth until right end bearing rests in
cradle of controls support bracket. (3). With stick in overcenter position,
remove cotter pin, nut, washer and bolt
(6). Check that two slotted bushings are in that secure male bearing to bungee
place in upper lugs of bungee bracket. overcenter fitting.
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FUSELAGE SKIN SNAP PLUG

COLLECTIVE CONTROL INTERCONNECTING
TORQUE TUBE
GAS PRODUCER INTERCONNECT

TORQUE TUBE
DROOP CONTROL
BUSHING OVERRIDE LINK
(NOTE 1) BRACKET (NOTE 4)
CLIP
NR DISABLE SWITCH (3 PLACES) TORQUE TUBE
AND BRACKET (NOTE 4) SUPPORT BEARING
0.30 IN. (7.62 MM)
ACTUATING CAM (NOTE 3) CONTROLS BRACKET CRADLE
(NOTE 4) INDEX GROOVE
PIPE PLUG
NOTE 5
THREADED
TORQUE TUBE SUPPORT
CONTROLS INSERT
BEARING
SUPPORT
INBOARD BRACKET
COLLECTIVE BUNGEE OVERCENTER
GAS PRODUCER STICK SOCKET ADJUSTMENT BOLT
CONTROL ROD ASSEMBLY
BUNGEE OVERCENTER
FITTING
FITTING MALE BEARING

NOTE 2
SLOTTED
BUSHING
RETAINER (NOTE 1)
SPRING
FEMALE
BEARING
ASSEMBLY
BUNGEE (NOTE 2)
INSTALLATION TOOL
RETAINER
(NOTE 2)
NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM
OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN.
(2.032 MM) ABOVE OUTSIDE SURFACE OF PART
AFTER NUT IS TIGHTENED.
2. LUBRICATION POINTS FOR GREASE.
3. PRELIMINARY ADJUSTMENTS ONLY. COMPRESSION TOOL
BUNGEE ASSEMBLYEXPLODED VIEW
4. USED ON 369D/E/FF 500N HELICOPTERS ONLY. ROD AND CHANNEL
5. WITH COLLECTIVE STICK AT FULL DOWN POSITION,
PRELIMINARY ADJUSTMENT OF BUNGEE
INSTALLATION IS:
G671006B
369D/E/FF 500N; 2.20 0.05 IN. (5.588 0.127 CM)
600N; 2.70 0.05 IN. (6.86 0.127 CM).
Figure 407. Collective Torque Tube, Gas Producer Torque Tube and Collective Bungee
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MAINTENANCE MANUAL
SNAP RING GAS PRODUCER INTERCONNECT

N1 PINION GEAR TORQUE TUBE
AFT BEARING
(NOTE 4)
PIPE PLUG
SNAP RING
SLOTTED
BUSHING
CLIP
(3 PLCS)
SOCKET HOUSING
SPACER
(NOTE 1)
BEARING (NOTE 4)
BACKLASH SHIM
FORWARD BEARING
(NOTES 2, 4)
SHAFT ASSEMBLY
BACKLASH SHIM
BEARING
LINK (NOTE 4)
NR DISABLE SWITCH
(NOTE 3) AND BRACKET
(NOTE 5)
ACTUATING CAM
(NOTE 5)
HOUSING CAP
IDLER
BELLCRANK
IDLER BEARING
(NOTE 4)
NOTES:
1. FOUR SPACERS USED ONLY ON REMOVED SOCKET ASSEMBLY TO KEEP ASSEMBLY INTACT.
2. N1 PINION FORWARD BEARING IS LIGHT PRESS FIT IN HOUSING BORE.
3. LINK MUST BE BOLTED TO BELLCRANK BEFORE BELLCRANK AND SHAFT ASSEMBLY ARE INSTALLED.
4. BEARINGS INSTALLED WITH LOCKING COMPOUND. THE TWO SHAFT ASSEMBLY BEARINGS BONDED
ONLY AFTER SHIMMING FOR BACKLASH. G671007B
5. USED ON 369D/E/FF 500N HELICOPTERS ONLY.
Figure 408. Inboard Collective Stick Socket Assembly (L/H Command)
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(4). Remove cotter pin, nut, two washers Do not turn female bearing as-
and bolt that attach female bearing end CAUTION sembly spring retainer while
of bungee to the bungee bracket. bungee installation tool is spring loaded.
(5). Remove collective bungee and installa- (6). Raise collective stick so that torque
tion tool as a unit. tube overcenter action compresses
spring until bungee installation tool can
(6). Remove cotter pin, nut and washer be removed; remove tool.
from overcenter fitting.
(7). With collective stick at full down
(7). Remove bolt that secure overcenter position, preliminary adjustment of
fitting to collective torque tube and bungee installation is:
remove fitting. 369D/E/FF 500N; 2.2 0.05 inch
(5.588 0.127 cm)
B. Collective OverCenter Fitting and 600N; 2.70 0.05 inch (6.86 0.127 cm).
Bungee Installation and Preliminary
Adjustment (8). Flight test helicopter and complete
adjustment of collective bungee.
Consumable Materials 12. Inboard Collective Stick Socket Assembly
(Ref. Section 910000) Replacement
Item Nomenclature
(Ref. Figure 408)
A. Inboard Collective Stick Socket Assembly
Special Tools Removal
Item Nomenclature (1). Remove pilots seat cover and controls
access door.
(2). Disconnect collective mixer tunnel
routed control rod.
(1). Lubricate sliding surfaces of overcen-
ter fitting with grease (CM116) and (3). Disconnect gas producer control rod
position on collective torque tube. from idler.
(2). Install bolt and washer though fitting (4). Remove NR disable switch (369D/E/FF
and torque tube, and adjust to obtain 500N only) (Ref. Chap. 95).
0.30 in. (7.62 mm) preliminary adjust-
ment between upper surface of fitting (5). Remove four nuts and washers that
and tips on torque tube fitting. attach socket assembly to collective
torque tube and remove assembly.
(3). Install washer and nut on bolt and
torque to 30 40 inchpounds (3.39
NOTE: If disassembly is not intended, install
four spacers and reinstall washers and nuts
4.52 Nm); install cotter pin.
on protruding bolts to keep assembly intact.
(4). Position collective bungee, compressed B. Inboard Collective Stick Socket Assembly
in installation tool (ST508), so that Installation
female bearing assembly is forward and
aligns with mating hole in bungee
bracket. Check that slotted bushing for Consumable Materials
bracket lug is in place, install bolt, two (Ref. Section 910000)
washers, nut and cotter pin. Item Nomenclature
CM318 Primer
(5). Position male bearing to align with
mating hole in bungee overcenter
fitting. Install bolt, washers, nut and (1). Remove four nuts washers and spacers
install cotter pin. from socket assembly mounting bolts.
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MAINTENANCE MANUAL
(2). With throttle grip on pilots collective (10). Connect gas producer control rod to
stick at midtravel, rotate bellcrank idler.
back and forth slightly to engage socket
assembly to gearshaft on hexagonal end (11). Connect collective mixer tunnelrouted
of gas producer interconnect torque control rod.
tube. Bellcrank centerline, N1 pinion (12). Remove bungee installation tool.
gear centerline toothspace and pilots
throttle must be as shown. (13). Reinstall pilots seat cover and the
controls access door.
NOTE:
D With pilots throttle grip at midtravel, two (14). Check that inboard collective pitch stick
grip attach bolts should be approximately socket gears are at midtravel when
straight down. Simultaneously, idlerto pilots collective pitch stick throttle grip
gas producer control rod bolt holes should is set to midtravel. If not, adjust
be in line with centerline of inboard stick collective pitch stick(s) gas producer
assembly housing cap. control linkage.
D At midtravel, inboard N 1 pinion gear (15). Adjust NR disable switch (369D/E/FF
spline wide toothspace should be at ap- 500N only) (Ref. Chap. 95).
proximately one oclock as viewed looking
aft into open end of socket. 13. Cyclic Control Stick Replacement
(Inboard)
(3). Install NR disable switch (369D/E/FF
500N only) (Ref. Sec. 95) and secure (Ref. Figure 409)
socket assembly housing to collective
A. Cyclic Control Stick Removal (Inboard)
torque tube.
(1). Disconnect control stick electrical plug.
(4). Rotate pilots throttle and check for zero
backlash between gas producer inter- (2). Remove hardware that secures pilots
connect torque tube and hexagonal lateral control rod to stick socket.
interior of drive gearshaft in socket
assembly housing. (3). Remove hardware that attaches lateral
friction mechanism link to cyclic torque
(5). Eliminate backlash by removing tube.
housing cap and gearshaft, and then
removing pipe plug in end of torque (4). Remove hardware that attaches stick
tube. socket to end of cyclic torque tube;
remove stick with lateral friction
(6). Coat pipe plug with wet zinc chromate mechanism attached.
primer (CM318), reinstall and tighten it
so there is no backlash between torque B. Cyclic Control Stick Installation (Inboard)
tube and control gearshaft at each end
(1). Position pilots cyclic control stick to
of the tube.
align with mating holes in torque tube.
(7). If the normally installed plug does not (2). Install attaching hardware.
sufficiently expand tube, a 1/827
internalwrenching pipe plug 0.38 inch (3). Check that slotted bushing is in place;
(9.65 mm) long may be substituted. then align pilots lateral control rod
Whichever plug is used, it must not with stick socket. Install attaching
protrude more than 0.030 inch (0.762 hardware.
mm) when tightened.
(4). Position guide link to align with mating
(8). Zero degree backlash is required at hole in torque tube. Install bolt, sleeve
both ends of tube. bushing three washers, nut and cotter
pin.
(9). After plug is tightened, reinstall
gearshaft and housing cap. (5). Connect electrical plug.
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CYCLIC STICK LATERAL CYCLIC

ASSEMBLY BELLCRANK
STRAP
LATERAL CONTROL ROD

(NOTE 2)
QUICK RELEASE NOTES:

PIN 1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM
OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.060 IN.
QUICK (1.524 MM) ABOVE OUTSIDE SURFACES OF PART
RELEASE AFTER NUT IS TIGHTENED.
SLOTTED BUSHING
PIN 2. CONTROL ROD END BEARINGS MUST NOT JAM
(NOTE 1)
THROUGHOUT FULL RANGE OF LONGITUDINAL
TRAVEL (34).
G671008A
Figure 409. Cyclic Stick Assembly Installation (Inboard)

14. Cyclic Control Stick Replacement (5). Remove stick tube from socket.
(Outboard)
B. Cyclic Control Stick Installation
(Ref. Figure 410) (Outboard)
A. Cyclic Control Stick Removal (Outboard) (1). Insert stick tube into stick socket and
install two quickrelease pins.
(1). Disconnect control stick electrical plug.
NOTE: Omit steps (2). thru (4). when installing
NOTE: Omit steps (2). and (3). below to remove stick without socket.
stick without removing stick socket. (2). Position cyclic stick to align holes in
(2). Remove cotter pin, nut, washers and socket with mating holes in torque
bolt securing copilots lateral control rod tube.
to stick socket. (3). Install bolt, two washers, nut and new
cotter pin.
(3). Remove cotter pin, nut, washers and
bolt attaching stick socket to end of (4). Check that slotted bushing is in place;
cyclic torque tube. Remove stick tube then align copilot s lateral control rod
with stick socket attached. with stick socket. Install bolt, two
washers, nut and new cotter pin.
(4). Remove two quickrelease pins attach-
ing stick tube to stick socket. (5). Connect electrical plug.
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CYCLIC PITCH
INTERCONNECTING
TORQUE TUBE CYCLIC STICK
ASSEMBLY
ONEWAY LOCK
ASSEMBLY
WASHER
LINK
STA. 67 LATERAL
CYCLIC BELLCRANK
LONGITUDINAL CONTROL
FRICTION MECHANISM
SLOTTED
BUSHING
(NOTE 1)
NOTES: LATERAL CONTROL

ROD (NOTE 2) LATERAL CONTROL
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF FRICTION MECHANISM
0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN. (2.032 MM) SLEEVE
ABOVE OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED. BUSHING
2. CONTROL ROD END BEARINGS MUST NOT JAM THROUGHOUT G671009B
FULL RANGE OF LONGITUDINAL TRAVEL (34).
Figure 410. Cyclic Stick Assembly Installation (Outboard)
15. Lateral Control Rods and Sta. 67 Lateral between rod end bearing centers for use
Cyclic Bellcrank Replacement (L/H at replacement.
Command)
B. Lateral Control Rods and Sta. 67 Lateral
(Ref. Figure 411) Cyclic Bellcrank Installation (L/H
Command)
A. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Removal (L/H Command)
(1). Check that slotted bushing is in upper
(1). Remove large (central) cyclic stick web of seat structure fitting. Align Sta.
guard. 67 lateral cyclic bellcrank and install
attaching hardware.
(2). Remove pilots seat cover, and controls
access door from Sta. 78.50 canted (2). Check that slotted bushings are in
bulkhead. place and install Sta. 70 lateral control
rod and pilots lateral control rod.
(3). Remove pilots lateral control rod, or
Sta. 70 lateral control rod, as applica-
(3). Move cyclic stick full forward, then full
ble.
aft and set pilots lateral control rod end
(4). Remove Sta. 67 lateral cyclic bellcrank bearing angularity so that bearings do
from seat structure fitting. not jam at full travel positions.
(5). If rod or rod ends require replacement, (4). If control rod or rod ends are replaced,
accurately measure and record distance perform a cyclic control rigging check.
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MAINTENANCE MANUAL
NOTES:
1. ASTERISK (*) IDENTIFIES SLOTTED BUSHING. EDGE OF BUSHING ELECTRICAL
MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO A PLUG
MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE SURFACE TUBE CYCLIC STICK SOCKET
OF PART AFTER NUT IS TIGHTENED. AND LATERAL FRICTION
2. WASHERS ARRANGED TO ALIGN LINK WITH TORQUE TUBE, RIVET INSTALLATION
PIN
LOOSELY SPACED WITH FOUR WASHERS.
CLAMP SOCKET
3. CONTROL RODS MUST NOT JAM THROUGHOUT FULL
RANGE OF LONGITUDINAL TRAVEL (34). FRICTION STUD
4. INSTALLED WITH LOCKING COMPOUND. FRICTION DISC
LATERAL GUIDE
RETAINER
NOTE 2
NUT
FRICTION
SPRING
FRICTION
KNOB *
PILOTS CYCLIC
STICK ASSEMBLY PILOTS CYCLIC
STICK GUARD BUSHING
LONGITUDINAL
CONTROL FRICTION
MECHANISM
CYCLIC STICK GRIP
LATERAL COPILOTS CYCLIC

CONTROL STICK ASSY
FRICTION
MECHANISM ELECTRICAL PLUG
PILOTS LATERAL
CONTROL ROD
(NOTE 3)
CYCLIC CONTROLS
CENTER GUARD COPILOTS CYCLIC
STICK GUARD
QUICK RELEASE PIN

FRICTION SPRING
FRICTION
KNOB QUICK RELEASE *
PIN
RETAINER
COUNTERSUNK
BOLT
FRICTION DISC COUNTERSUNK
NUT LATERAL
NOTE 2 WASHER IDLER
BELLCRANK
FRICTION STUD BEARING
LONGITUDINAL GUIDE *
(NOTE 4)
*
SPRING *
PIN
BUSHING RIVET STA 70 LATERAL

CONTROL ROD
LONGITUDINAL FRICTION INSTALLATION
PILOTS LATERAL STA 67 LATERAL CYCLIC
CONTROL ROD BELLCRANK
LATERAL BELLCRANK CONNECTIONS

G671010A
Figure 411. Cyclic Controls (R/H Command)
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MAINTENANCE MANUAL
16. Lateral Control Rods and Sta. 67 Lateral each end with a bolt, two washers, nut
Cyclic Bellcrank Replacement (R/H and new cotter pin.
Command)
(3). Move both cyclic sticks full forward,
(Ref. Figure 411) then full aft and set both lateral control
rods so that rod end bearings do not
jam at full throw positions; hold rod
A. Lateral Control Rods and Sta. 67 Lateral ends and tighten jam nuts.
Cyclic Bellcrank Removal (R/H
Command) (4). If control rod or rod ends were replaced,
perform cyclic control rigging check.
(1). Remove cyclic stick guards.
(5). Install cyclic stick guards, pilots
(2). Install large (central) cyclic stick guard collective pitch stick cover, controls
pilots seat cover and controls access access door, and foot fairing.
door.
17. Cyclic Pitch Interconnecting Torque Tube
(3). Remove pilots collective pitch stick Replacement (L/H Command)
cover, and controls access door and left
foot support fairing from Sta. 78.50 (Ref. Figure 412)
canted bulkhead.
A. Cyclic Pitch Interconnecting Torque Tube
Removal (L/H Command)
(4). Remove cotter pin, two washers and
bolt from each end of pilots lateral (1). Remove pilots seat cover.
control rod, copilots lateral control rod,
or Sta. 70 lateral control rod, as
(2). Position pilots cyclic stick to align holes
applicable; remove rod assembly.
in oneway lock support links with bolt
that attaches forward end of oneway
(5). Remove cotter pin, nut, two washers lock to torque tube; tighten longitudinal
and bolt securing Sta. 67 lateral cyclic friction. Disconnect rod end from torque
bellcrank to seat structure fitting; tube arm.
remove bellcrank.
(3). Remove pilots cyclic stick.
(6). If rod or rod ends require replacement,
accurately measure and record distance (4). Remove all of cyclic stick guard instal-
between rod end bearing centers for lation except small guard next to pilots
future reference; use trammel method, cyclic stick.
or equivalent.
(5). Remove longitudinal control friction
B. Lateral Control Rods and Sta. 67 Lateral mechanism.
Cyclic Bellcrank Installation (R/H
Command) (6). Remove pilots lateral control rod from
Sta. 67 lateral cyclic bellcrank.
(1). Check that slotted bushing is in upper (7). Cut lockwire and remove support nuts,
web of seat structure fitting. Align Sta. support bolts and two wide (L/H)
67 lateral cyclic bellcrank and install support spacers from seat structure
bolt, two washers, nut and new cotter fitting lugs and torque tube. Prevent
pin. torque tube from dropping as bolts are
removed.
(2). Check that slotted bushings are in
place and install Sta. 70 lateral control (8). Remove torque tube and two narrow
rod. Install both lateral control rods at (R/H) support spacers.
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NOTES: CONTROLS
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF SUPPORT
0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN. (2.032 MM) BRACKET
ABOVE OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. MAY BE INSTALLED IN EITHER DIRECTION.
3. MAY BE INTERCHANGED TO ALIGN ONEWAY LOCK.
4. INSTALLED WITH GREASE ON OUTSIDE CIRCUMFERENCE.
5. INSTALLED WITH LOCKING COMPOUND.
6. SHIM WASHERS AS REQUIRED TO ALIGN ONEWAY LOCK (REMOVE
SIDELOAD).
CAUTION:
DO NOT HAMMER RIVETS: SQUEEZE ONLY.
LONGITUDINAL IDLER
BELLCRANK
SHIM WASHER
(NOTE 6)
ONEWAY
LOCK SLOTTED BUSHING
INPUT END (NOTE 1)
CYCLIC STICK
PIVOT BEARING
OUTPUT
END
SHIM WASHER
(NOTE 6)
SLOTTED BUSHING
CYCLIC PITCH (NOTE 1) SLEEVE PIVOT BUSHING
INTERCONNECTING BUSHING
SUPPORT LINK
TORQUE TUBE
SUPPORT BEARING
(NOTE 5)
FLANGE
RETAINER
BUSHING
SUPPORT BOLT
(NOTE 2)
SUPPORT SPACER,
0.20 IN. (5.08 MM) WIDE
CYCLIC STICK
(NOTE 3)
PIVOT BEARING
SUPPORT SPACER, 0.430 IN. SUPPORT BEARING
(10.29 MM) WIDE (NOTE 4)
SUPPORT NUT
SUPPORT RIVET
NUT
RIVET STUD
(SEE CAUTION)
SUPPORT SPACER,
0.260 IN. (6.60 MM) WIDE SUPPORT BOLT SPRING PIN
(NOTE 3) (NOTE 2)
SUPPORT SPACER, 0.520 IN. STUD (FRICTION
(13.21 MM) WIDE MECHANISM) (TYPICAL)
G671011A
Figure 412. Cyclic Torque Tube and OneWay Lock Installation
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MAINTENANCE MANUAL
B. Cyclic Pitch Interconnecting Torque Tube oneway lock support links; install
Installation (L/H Command) attaching hardware.
(9). Install pilots seat cover.
(Ref. Section 910000) 18. Cyclic Pitch Interconnecting Torque Tube
Item Nomenclature Replacement (R/H Command)
CM702 Lockwire CRES (Ref. Figure 411)
A. Cyclic Pitch Interconnecting Torque Tube
(1). Align cyclic torque tube support Removal (R/H Command)
bearings with holes in structure fitting
lugs. Place narrow support spacer on Removal of torque tube is essentially the same
right side of each support bearing, and as L/H command except note the following:
install two wide support spacers and (1). Remove pilots collective pitch stick
support bolts. cover.
NOTE: Support bolts may be installed from ei- (2). Remove pilots cyclic stick and copilots
ther direction, and two narrowest (R/H) sup- cyclic stick.
port spacers are to be interchanged for best
alignment of torque tube with oneway lock. (3). Remove cyclic stick guards.
(4). Remove longitudinal control friction
(2). Check that slotted bushing is in torque mechanism.
tube arm, and fit oneway lock rod end
against unbushed lug of arm. If tighten- (5). Remove both lateral control rods from
ing of attachment bolt will apply Sta. 67 lateral cyclic bellcrank.
sideload on the rod end, interchange
two narrowest (R/H) support spacers, B. Cyclic Pitch Interconnecting Torque Tube
and/or adjust lateral position shimming Installation (R/H Command)
of longitudinal idler bellcrank or Installation of torque tube is essentially the
oneway lock rod ends until there is no same as L/H command except note the
sideload on oneway lock control following:
system. Check that no structural
interference results from spacer (1). Install pilots and copilots lateral
interchange. control rods (riveted rod ends) to Sta.
67 lateral cyclic bellcrank.
(3). Without sideload on oneway lock,
install and tighten support nuts. Using (2). Install longitudinal control friction
lockwire (CM702), safetywire each nut mechanism.
to hole in threaded end of mating bolt. (3). Install cyclic stick guards.
When installing lockwire do not
damage aluminum nut and bolt. (4). Install pilots cyclic stick and copilots
cyclic stick.
(4). Install pilots lateral control rod (riveted
rod) end to Sta. 67 lateral cyclic (5). Install pilots collective pitch stick
bellcrank. cover.
(5). Install longitudinal control friction 19. OneWay Lock Replacement

mechanism. (Ref. Figure 412)
(6). Install cyclic stick guards. A. OneWay Lock Removal
(7). Install pilots cyclic stick. (1). Remove pilots seat cover or inboard
collective pitch stick cover and controls
(8). Position pilots cyclic stick to align bolt access door from Sta. 78.50 canted
holes in torque tube arm with holes in bulkhead.
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MAINTENANCE MANUAL
(2). Remove cyclic stick guard. NOTE: Two narrowest (R/H) cyclic torque tube
support spacers may also be interchanged to
(3). Position pilots cyclic stick to align holes align oneway lock.
in oneway lock support links with bolt
that attaches forward end of oneway (7). Without sideload on oneway lock,
lock to cyclic torque tube; tighten secure each rod end bearing with
longitudinal friction. Disconnect rod attaching hardware.
end from torque tube arm. (8). Check reservoir fluid level (Ref. Sec.
(4). Disconnect oneway lock lower rod end 120000).
from longitudinal idler bellcrank. (9). Install cyclic stick guard.
(5). Disconnect upper end of each support (10). Install pilots seat cover or inboard
link from seat structure and remove collective pitch stick cover and control
oneway lock with links attached. access door.
(6). Remove two cotter pins, washers and 20. Cyclic Trim Actuator Replacement
links. Do not remove pivot bushings
from links unless replacement is (Ref. Figure 403)
necessary. A. Cyclic Trim Actuator Removal
B. OneWay Lock Installation (1). Jack helicopter (Ref. Sec. 070000)
until landing gear is fully extended and
(1). Check that rod end bearing centerto clears ground.
center distance is correct.
(2). Remove foot fairing, controls access
(2). Attach lower ends of links to oneway door from Sta. 78.50 canted bulkhead
lock with bushings, washers and cotter and open pilots compartment floor
pins. access door.
(3). Align upper ends of links with mating (3). Disconnect bonding jumper and
holes in seat structure fitting and electrical connector from actuator
attach each link with bolt, sleeve housing.
bushing, washer, nut and cotter pin. (4). Disconnect upper end of trim actuator.
(4). Check that slotted bushing is in place Keep pivot bushing with actuator
in longitudinal idler bellcrank; then fit unless actuator is being replaced.
lower rod end bearing against un- (5). Disconnect lower end of trim actuator.
bushed lug of bellcrank to check if Access to attaching nut is through hole
sideloading occurs when attachment in underfloor compartment aft
bolt is tightened. There must be no bulkhead, near centerline beam.
sideloading of oneway lock mecha-
nism. Arrange shim washers, as (6). Remove trim actuator. Reinstall
necessary, to position longitudinal idler original lower end attaching hardware
bellcrank and/or lower rod end for if actuator is being replaced; new
alignment without sideload. actuator includes this hardware.
(5). Position pilots cyclic stick to align holes B. Cyclic Trim Actuator Installation
in support links with hingeline for (1). Check trim actuator spring assembly
upper end of oneway lock and cyclic for free play between spring and spring
torque tube arm; tighten longitudinal adapters. Adjust spring adapter screw
friction. until 0.0100.050 inch (0.2541.27 mm)
is felt while pushing or pulling on
(6). Repeat check for sideload on oneway spring assembly.
lock, step (4)., and arrange shim
washers, if necessary, to position upper (2). Remove hardware supplied in housing
rod end for alignment without sideload. end of new trim actuator.
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MAINTENANCE MANUAL
(3). Check that slotted bushings are in NOTE: Lateral actuator upper hingeline has
place in actuator housing. Place one 3/16 inch (4.7625 mm) bolt hole; longitudi-
washer around each side of pivot nal has 1/4 inch (6.35 mm) bolt hole.
bearing in center beam support lug and
align actuator housing with bearing. (5). Connect bonding jumper. Connect
Install bolt, two washers and nut (and electrical plug to actuator.
cotter pin if old style).
(4). Align actuator with idler bellcrank. (6). With main rotor blades lifted off droop
Check that slotted bushing is in stops, perform poweron operational
bellcrank lug; install actuator pivot check of cyclic trim actuator. Actuator
bushing if actuator is a replacement. must not bind throughout travel range
Pivot bushing must rotate freely in in either direction, and must maintain
actuator. Install bolt, two washers, nut at least 0.015 inch (0.381 mm)minimum
and cotter pin. After bolt is tightened, clearance with center beam structure.
pivot bushing must not rotate in idler
bellcrank. (7). Lower helicopter and remove jacks.
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MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Cyclic and Collective Control System (2). Release friction and raise pilots
Rigging collective stick. Position collective
rigging fixture (ST501) in outboard
Rigging of the main rotor control system must lower end of slot in collective friction
be accomplished immediately after replace- guide link (view C).
ment of linkage that cannot be accurately
measured (by trameling, etc.) before it is (3). Lower collective stick on rigging fixture
installed in the main rotor control system, or if and tighten friction grip (drive gear).
helicopter operation reveals rigging deficiency.
NOTE: (4). Position mixer rigging plate (ST503) on

mast support fitting.
D Cyclic and collective controls must be
rigged in sequence, starting with collec-
tive controls. Control rod end bearing ad- NOTE: When installing the mixer rigging plate
justments are to be made to nearest half on the 500N helicopter, removal of the split-
turn that produces correct rigging. When ter bungee and bracket is required. (Ref. Sec
tightening jam nut at adjustable end of 672030).
control rods, always hold rod end with
wrench to prevent jamming of bearing. (5). Measure and record distance from
D On the 600N helicopter, make all rigging horizontal centerline of mast support
adjustments using the roofmounted con- bracket hingeline bolt (attaching
trol rods. longitudinal idler bellcrank and
collective pitch mixer bellcrank to mast
D On the 600N helicopter, tunnelrouted support bracket) to surface of mixer
control rods should only be adjusted if a plate (view A). This dimension shall be
flight control component, forward of the used as the basic dimension in rigging
roofmounted bellcranks, has been re- the mixer controls.
placed.
(6). Measure distance from horizontal
2. Collective Controls Rigging (L/H centerline of bolt that attaches collec-
Command) (369D/E/FF 500N) tive pitch mixer bellcrank to longitudi-
nal pitch mixer bellcrank (view B) to
(Ref. Figure 501) surface of mixer rigging plate; it should
be same as basic dimension recorded in
step (5). above. If not, loosen checknut,
Special Tools disconnect upper end of collective
(Ref. Section 910000) control rod and adjust rod end (to
Item Nomenclature nearest halfturn of rod end bearing)
ST501 Collective rigging fixture until dimensions are equal.
(LH command)
ST503 Mixer rigging plate (7). Reconnect control rod, remove collective
stick rigging fixture and check mixer
travel. With stick at down stop, center-
(1). Remove main rotor blades, or manually line of collective pitch mixer bellcrank
raise blades off droop stops by simulta- bolt (view B) should move down so that
neously lifting blade tips. All five blades dimension recorded in step (5). above
must be off stops during rigging. decreases not less than 0.74 inch
Padded supports should be used. (18.796 mm).
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671000 Revision 21
MAINTENANCE MANUAL
LONGITUDINAL MAST SUPPORT

PITCH IDLER BRACKET
BELLCRANK
NOTE 1
BOLT (HEAD LEFT),

WASHERS, NUT,
COTTER PIN
MIXER RIGGING
MAST SUPPORT PLATE
INITIAL RIGGING PLATE MEASUREMENT
FITTING
LONGITUDINAL PITCH
MIXER BELLCRANK
COLLECTIVE PITCH
MIXER BELLCRANK
COLLECTIVE PITCH
CONTROL ROD
NOTE 1
COLLECTIVE
RIGGING
FIXTURE
RIGGING PLATE MEASUREMENT

FIXTURE INSTALLATION
CONTROL
FRICTION GRIP
(DRIVE GEAR)
NOTES: COLLECTIVE FRICTION

1. ACTUAL DISTANCE TO BE MEASURED PILOTS COLLECTIVE GUIDE LINK
AND RECORDED. PITCH STICK
2. TO BE SAME AS ACTUAL DISTANCE
MEASURED (VIEW A). (REFER TO TEXT)
3. ELASTOMER RING THIS SIDE ON G6710121
CURRENT CONFIGURATION ONLY.
Figure 501. Main Rotor Control System Rigging (369D/E/FF 500N) (Sheet 1 of 3)
Page 502
Revision 21 671000
MAINTENANCE MANUAL
LONGITUDINAL
PITCH IDLER
NOTE 2
BOLT (HEAD LEFT),

WASHERS, NUT,
MIXER RIGGING PLATE COTTER PIN
LONGITUDINAL PITCH LONGITUDINAL PITCH
MIXER BELLCRANK CONTROL MIXER
MIXER TRAVEL
PITCH CONTROL ROD
ELASTOMER RING
(NOTE 3)
ELASTOMER RING
SLOTTED BUSHING
LATERAL BELLCRANK
LONGITUDINAL
FRICTION GUIDE STATIONARY
LINK PITCH CONTROL ROD SWASHPLATE
INSTALLATION (5 PLACES)
MIXER LINK
NOTE 2
KNURLED THUMBNUT
FRICTION
KNOB
MIXER TRAVEL
CYCLIC STICK LONGITUDINAL
RIGGING FIXTURE
LONGITUDINAL RIGGING
FIXTURE INSTALLATION LATERAL PITCH
CONTROL ROD
FRICTION KNOB
LATERAL FRICTION
GUIDE LINK
KNURLED THUMBNUT CYCLIC STICK LATERAL

RIGGING FIXTURE
LATERAL RIGGING
G6710122
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671000 Revision 21
MAINTENANCE MANUAL
0.75 IN. (19.05 MM)

0.75 IN. (19.05 MM) 1.190 IN.
(30.226 MM)
FWD
0.45 IN. (11.43 MM)
0.74 IN. 0.76 IN. (19.304 MM)
1.190 IN.
(18.796 MM) (30.226 MM)
UP 0.43 IN.
(10.922 MM) 2.25 IN.
0.74 IN. (18.796 MM) (57.15 MM)
RT
0.43 IN. (10.922 MM) REF
NOM NOM NOM
0.50 IN. (12.70 MM) 0.57 IN.

0.74 IN. (18.796 MM) (14.478 MM)
0.50 IN. 0.57 IN. 1.92 IN. (48.564 MM) REF
0.74 IN. (12.70 MM) (14.478 MM)
(18.796 MM) LFT AFT
DN
SIDE VIEW
0.32 IN. FRONT VIEW 1.05 IN
(8.128 MM) (26.67MM)
0.125 IN.
2.25 IN. (57.15 MM)
(3.175 MM)
1.00 IN.
GENERAL NOTES FOR BUILDING FIELD RIGGING AID: (25.4 MM)
1. MAKE FROM TANGLE STOCK TO DIMENSIONS SHOWN.
2. SCREWS, NUTS AND WASHERS AS REQUIRED.
3. HOLES IN VERTICAL TANGLE TO BE SLOTTED TO ADJUST 2.25 IN.
TO MIXER SUPPORT BOLT NOMINAL DIMENSION. (57.15 MM)
4. SCRIBE MARKING ON VERTICAL TANGLE AS SHOWN.
5. MANUFACTURE FROM 2024T4 AL ALY PLATE.
6. IMPRESSION STAMP PART NO. AND INSTRUCTIONS.
SURFACE TO BE FLAT AFTER STAMPING.
TOP VIEW
0.81 IN. (20.57 MM) .09 R 0.375 IN. (9.525 MM)

NOTE 5
6.71 IN. (170.43 MM) 1.75 IN. (44.45 MM)
1.12 IN. (28.45 MM)
1.75 IN. (44.45 MM)
NOTE 6
2.75 IN. (69.85 MM)
369A9930
THIS SIDE UP 4.18 IN.
(106.17 MM)
2.18 IN. (55.37 MM)
.09 R
8.56 IN. (217.42 MM)
90
11.38 IN. (289.05 MM)
2.18 IN. (55.37 MM)

FIELD RIGGING AID 0.94 IN. (23.88 MM)
G6710123E
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MAINTENANCE MANUAL
MIXER
RIGGING PLATE
MAST MAST
SUPPORT FITTING SUPPORT
BRACKET
LONGITUDINAL PITCH
IDLER BELLCRANK
NOTE 1
COLLECTIVE MIXER
CONTROL ROD
MIXER RIGGING
PLATE
INITIAL RIGGING PLATE MEASUREMENT
LONGITUDINAL PITCH
MIXER BELLCRANK
COLLECTIVE PITCH
COLLECTIVE FRICTION MIXER BELLCRANK
GUIDE LINK
NOTE 2
PILOTS COLLECTIVE
PITCH STICK
CONTROL FRICTION GRIP
(DRIVE GEAR)
RIGGING PLATE MEASUREMENT
COLLECTIVE RIGGING
NOTES:
FIXTURE
1. ACTUAL DISTANCE TO BE MEASURED AND RECORDED.
2. TO BE SAME AS ACTUAL DISTANCE MEASURED
IN VIEW A (REFER TO TEXT).
3. ELASTOMER RING THIS SIDE ON CURRENT
CONFIGURATION ONLY.
6G670371B
Figure 502. Rigging Main Rotor Control System (600N) (Sheet 1 of 3)
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671000 Revision 34
MAINTENANCE MANUAL
LONGITUDINAL MIXER LONGITUDINAL KNURLED

CONTROL ROD FICTION GUIDE THUMBNUT
(CYCLIC) LINK
LATERAL MIXER
CONTROL ROD
(CYCLIC)
FRICTION KNOB
LONGITUDINAL RIGGING
NOTE 2
LATERAL FRICTION FRICTION KNOB

GUIDE LINK
LONGITUDINAL PITCH
MIXER BELLCRANK MIXER RIGGING PLATE
MIXER TRAVEL
KNURLED CYCLIC STICK LATERAL

THUMBNUT RIGGING FIXTURE
LATERAL RIGGING
PITCH CONTROL ROD
LATERAL BELLCRANK
ELASTOMER RING
(NOTE 3)
ELASTOMER
RING
STATIONARY
SLOTTED SWASHPLATE
BUSHING MIXER LINK
NOTE 2
PITCH CONTROL ROD

INSTALLATION (6 PLACES) MIXER RIGGING PLATE
MIXER TRAVEL
6G670372A
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Revision 21 671000
MAINTENANCE MANUAL
0.75 IN. (19.05 MM) 1.05 IN. 0.75 IN. (19.05 MM)
(26.67 MM)
FWD
0.48 IN. (12.192 MM)
1.05 IN.
0.83 IN. 0.79 IN. (20.066 MM)
(26.67 MM)
(21.082 MM)
DN 0.37 IN 2.25 IN.
(9.398 MM) (57.15 MM)
0.83 IN. (21.082 MM) RT REF
0.37 IN (9.398 MM)
NOM NOM NOM
0.52 IN. (13.208 MM) 0.65 IN.

0.71 IN. (18.034 MM) 0.52 IN. (16.51 MM)
0.65 IN.
(13.208 MM) (16.51 MM)
0.71 IN. LFT
(18.034 MM) AFT
UP
0.50 IN. (12.7 MM)
0.29 IN. SIDE VIEW

(7.366 MM) FRONT VIEW
0.125 IN.
(3.175 MM) 2.25 IN. (57.15 MM)
1.00 IN.
(25.4 MM)
GENERAL NOTES FOR BUILDING FIELD RIGGING AID:

1. MAKE FROM TANGLE STOCK TO DIMENSIONS SHOWN. 2.25 IN.
2. SCREWS, NUTS AND WASHERS AS REQUIRED. (57.15 MM)
3. HOLES IN VERTICAL TANGLE TO BE SLOTTED TO ADJUST
TO MIXER SUPPORT BOLT NOMINAL DIMENSION.
4. SCRIBE MARKING ON VERTICAL TANGLE AS SHOWN.
5. MANUFACTURE FROM 2024T4 AL ALY PLATE.
6. IMPRESSION STAMP PART NO. AND INSTRUCTIONS.
SURFACE TO BE FLAT AFTER STAMPING.
TOP VIEW
0.375 IN. (9.525 MM)

0.81 IN. (20.57 MM) .09 R
NOTE 5 1.75 IN. (44.45 MM)
6.71 IN. (170.43 MM)
1.12 IN. (28.45 MM)
1.75 IN. (44.45 MM)
NOTE 6
2.75 IN. (69.85 MM)
369A9930
THIS SIDE UP 4.18 IN.
(106.17 MM)
2.18 IN. (55.37 MM)
.09 R
8.56 IN. (217.42 MM)
90
11.38 IN. (289.05 MM)
2.18 IN. (55.37 MM)
FIELD RIGGING AID 0.94 IN. (23.88 MM)

6G670373B
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MAINTENANCE MANUAL
COLLECTIVE
FRICTION GUIDE
COLLECTIVE RIGGING
FIXTURE
COLLECTIVE RIGGING
LONGITUDINAL
FRICTION FRICTION KNOB
KNOB
LATERAL
FRICTION
GUIDE LINK CYCLIC STICK
LONGITUDINAL
RIGGING FIXTURE
CYCLIC STICK LATERAL

RIGGING FIXTURE
LONGITUDINAL FRICTION
GUIDE LINK
CYCLIC STICK LATERAL RIGGING
RIGGING FIXTURE INSTALLATION G671013
Figure 503. Cyclic and Collective Controls Rigging Tools (R/H Command)
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MAINTENANCE MANUAL
NOTE: To facilitate field rigging of the collec- used in inboard lower end of collective friction
tive control (up and down) and the cyclic guide slot.
control (both forward and aft, and right and
left) a field rigging aid may be fabricated as 4. Collective Control System Rigging (L/H
illustrated (Ref. Figure 501, Sheet 3). If the Command) (600N)
mixer bellcranks are in dimension with ref-
(Ref. Figure 502)
erence to the mixer rigging plate (ST503)
the collective and cyclic controls are proper-
ly rigged. The dimension attained in steps Special Tools
(7). and (8). shall correspond to the dimen- (Ref. Section 910000)
sions marked on the field rigging aid. If the Item Nomenclature
dimensions attained do not correspond, full ST501 Collective rigging fixture
rigging procedures must be performed. (LH command)
ST503 Mixer rigging plate
(8). With stick at up stop, centerline of ST504 Longitudinal rigging fixture
collective pitch mixer bellcrank bolt (LH command)
should move up so that dimension ST506 Lateral rigging fixture
recorded in step (5). above increases (LH command)
minimum of 0.74 inch (18.796 mm). ST511 Test fixture
Do not adjust control rod end be-

CAUTION yond witness hole. Tighten jam- (1). Remove main rotor blades, or manually
nut after final adjustment. Failure to ob- raise blades off droop stops by simulta-
serve this precaution can result in parts neously lifting blade tips. All six blades
damage and/or equipment failure. must be off stops during rigging.
Padded supports should be used.
(9). If necessary, adjust rod end of collective
pitch control rod to meet limits speci- (2). Release friction and raise pilots
fied in steps (7). and (8). above. When collective stick. Position collective
adjustment is complete, tighten jamnut rigging fixture (ST501) in outboard
and make certain that length of control lower end of slot in collective friction
rod does not change. guide link (view C).
(10). Remove mixer rigging plate. On the

NOTE: The collective bungee has very high
overcenter spring pressure. Ensure collec-
500N helicopter reinstall the spitter
tive stick is fully seated on rigging fixture or
bungee and bracket. (Ref. Sec
rigging may not be correct.
672030).
(3). Lower collective stick on rigging fixture
(11). Reconnect collective pitch control rod. and tighten friction lock.
3. Collective Controls Rigging (R/H (4). Adjust longitudinal cyclic trim for
Command) (369D/E/FF 500N) noload and install longitudinal cyclic
rigging fixture (ST504) (Ref. View D).
(5). Adjust lateral cyclic trim for noload
Special Tools and install lateral cyclic rigging fixture
(Ref. Section 910000) (ST506) (Ref. View E).
Item Nomenclature NOTE: For both longitudinal and lateral cyclic
ST502 Collective rigging fixture rigging fixtures, ensure that the bolt of the
(RH command) friction lock is engaged in the slot of the rig-
ging fixture and that the hook of the fixture
is properly engaged with the checknut tight-
Collective control rigging for the R/H command ened.
helicopter is accomplished according to
instructions for L/H command helicopters, (6). Position mixer rigging plate (ST503) on
except collective rigging fixture (ST502) is mast support fitting.
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671000 Revision 21
MAINTENANCE MANUAL
NOTE: To facilitate field rigging of the collec- (a). With collective stick at downstop,
tive control (up and down) and the cyclic centerline of bolt in collective bell-
control (both forward and aft and right and crank (369N2664) shall move down a
left) a field rigging aid may be fabricated as minimum of 0.71 inch (18.0 mm)
illustrated (Ref. Figure 502, Sheet 3). If the below nominal setting.
mixer bellcranks are in dimension with ref-
(b). With collective stick at upstop,
erence to the mixer rigging plate (ST503)
centerline of bolt in collective bell-
the collective and cyclic controls are proper-
crank (369N2664) shall move up a
ly rigged. The dimension attained in the fol-
minimum of 0.83 inch (21.0 mm)
lowing paragraphs shall correspond to the
above nominal setting.
dimensions marked on the field rigging aid.
If the dimensions attained do not corre- 5. Collective Controls Rigging (R/H
spond, full rigging procedures must be per- Command) (600N)
formed.
(Ref. Figure 502 and Figure 503) Collective
control rigging for the R/H command helicopter
(7). Using a six inch (16 cm) scale, measure is accomplished according to instructions for
and record distance from rigging L/H command helicopters, except the following
platetocollective hinge bolt center, rigging fixtures must be substituted.
this is your nominal setting, or, position
test fixture (ST511) on rigging plate
and adjust NOM indicator to centerline Special Tools
of collective hinge bolt. (Ref. Section 910000)
Item Nomenclature
Do not allow test fixture points
CAUTION to scribe or mark the bolts.
(RH command)
NOTE: Do not change the setting of the test fix- (RH command)
ture. This setting will be the basic NOMI-
NAL for locating, to the nearest half turn of
(RH command)
the respective control rod end fitting, the
height of the bolts. ST511 Test fixture
(a). Adjust collective control rod so 6. Cyclic Controls Rigging (L/H Command)
centerline of bolt of the collective (369D/E/FF 500N)
bellcrank (369N2664) is at NOM, to
(Ref. Figure 501)
nearest halfturn on rod end bearing.
Special Tools
(b). Adjust longitudinal control rod so (Ref. Section 910000)
centerline of bolt of the longitudinal Item Nomenclature
bellcrank (369N2666) is at NOM, to
nearest halfturn on rod end bearing. ST501 Collective rigging fixture
(LH command)
(c). Adjust lateral control rod so center-
line of bolt of the lateral bellcrank
(LH command)
(369N2670) is at NOM, to nearest
halfturn on rod end bearing. ST506 Lateral rigging fixture
(LH command)
(8). Remove collective rigging fixture and

check travel as follows: NOTE: All cyclic control rigging is done with
collective controls at midposition.
NOTE: Adjust rod end, as required, to obtain (1). Remove main rotor blades, or manually
the following limits. raise blades off droop stops by simulta-
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MAINTENANCE MANUAL
neously lifting blade tips. All five blades NOTE: Field rigging aid (Ref. Figure 501,
must be off stops during rigging. Sheet 3) may be used to check dimensions
Padded supports should be used. attained in steps (4). and (5).. If dimensions
attained do not correspond with dimensions
(2). Release friction and raise pilots shown on rigging aid, full rigging proce-
collective stick. Position collective dures must be performed.
lower end of slot in collective friction (9). Reposition mixer rigging plate to clear
guide link (view C). longitudinal pitch mixer bellcrank.
With stick at aft stop, centerline of
(3). Lower collective stick on rigging fixture longitudinal pitch mixer bellcrank bolt
and tighten friction grip (drive gear). (view B) should move down so that
basic dimension recorded in step (3).
(4). Position mixer rigging plate (ST503) on above decreases minimum of 0.570 inch
mast support fitting. (14.478 mm).
(5). Loosen longitudinal friction knob and Do not adjust control rod beyond
CAUTION witness hole. Tighten jamnut af-
set longitudinal cyclic trim for no load
by neutralizing cyclic stick. Position ter final adjustment. Failure to observe this
cyclic stick so that longitudinal rigging precaution can result in parts damage and/
fixture (ST504) fits in outboard side of or equipment failure.
slot in longitudinal friction guide link.
(10). If necessary, adjust rod end of longitudi-
(Index pin of fixture butts against
nal pitch control rod to meet limits
forward end of slot, and friction knob
specified in steps (4). and (5). above.
stud fits in fixture detent view F.)
Adjust carefully; tolerance is only 1/2
(6). Secure fixture hook in aft end of slot. turn. When adjustment is complete,
Tighten knurled thumbnut to seat tighten jamnut and ensure that length
bushing at forward end and tighten of control rod does not change.
friction knob. (11). Reconnect control rod to longitudinal
pitch idler.
(7). Measure and record distance from
horizontal centerline of bolt at aft end (12). Reinstall longitudinal rigging fixture;
of longitudinal pitch mixer bellcrank reposition and secure mixer rigging
(view H) to surface of mixer rigging plate.
plate. It should be same as distance
from horizontal centerline of mast (13). Loosen friction knob and set lateral
support bracket hingeline bolt to cyclic trim for no load by neutralizing
surface of mixer plate (Ref. Collective cyclic stick. Position cyclic stick so that
Controls Rigging (L/H Command), step lateral rigging fixture (ST506) fits in
(5).). If not, loosen jamnut, disconnect forward side of slot in lateral friction
longitudinal pitch control rod and guide link. (Index pin of fixture butts
adjust rod end, to nearest half turn of against outboard end of slot, and
rod end bearing, until dimensions are friction knob stud fits in fixture detent
equal. This will be basic dimension for view E.)
cyclic control rigging. (14). Secure fixture hook in inboard end of
slot, tighten knurled thumbnut to seat
(8). Reconnect control rod, remove longitu- bushing at outboard end, and tighten
dinal stick rigging fixture and check friction knob.
mixer travel. With stick at forward
stop, centerline of longitudinal pitch (15). Measure distance from horizontal
mixer bellcrank bolt (view B) should centerline of bolt connecting lateral
move up so that basic dimension bellcrank to stationary swashplate
recorded in step (7). above is increased mixer link to (view D) surface of mixer
minimum of 1.19 inches (3.0226 cm), or rigging plate; it should be same as basic
a maximum of 1.22 inches (3.0988 cm). dimension recorded in step (3).. If not,
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loosen checknut, disconnect lateral Check for interference between

pitch control rod and adjust rod end (to CAUTION rod end bearings and lugs of
nearest halfturn on rod end bearing) pitch control housing. Adjust bearings as re-
until dimensions are equal. quired to provide clearance.
NOTE: Next step establishes initial adjust-

(16). Reconnect control rod, remove lateral ment of main rotor pitch controls links. Fi-
stick rigging fixture and check mixer nal adjustment is to be made by tracking
travel. With stick at left stop, centerline and autorotation rpm setting (Ref. Sec.
of lateral bellcrank bolt (view D) should 181000).
move down so that basic dimension
(21). Remove and adjust length of each pitch
recorded in step (3). decreases a
control link (view G) so that centerline
minimum of 0.50 inch (12.70 mm) or a tocenterline distance between rodend
maximum of 0.53 inch (13.462 mm). bearings is 6.25 inches (15.875 cm).
Then install the pitch control links.
NOTE: The field rigging aid (Ref. Figure 501, (22). With collective stick full down and
sheet 3) may be used to check dimensions cyclic stick full forward and full left,
attained in steps (12). and (13).. If the di- check clearance between the rotating
mensions attained do not correspond with swashplate and the longitudinal pitch
dimensions shown on the rigging aid, full idler bellcrank. Minimum clearance is
rigging procedures must be performed. 0.125 inch (3.175 mm). Adjust the
collective control rod as required.
(17). With stick at right stop, centerline of (23). With collective stick full up and cyclic
lateral bellcrank bolt should move up so stick full left (any position fore or aft),
that basic dimension recorded in step check clearance between lateral
(3). increases minimum of 0.43 inch bellcrank and, collective pitch mixer
(10.922 mm). bellcrank of the mixer controls. Mini-
mum clearance is 0.030 inch (0.762
mm). Adjust lateral control rod as
Do not adjust control rod beyond required.
ter final adjustment. Failure to observe this (24). With collective stick full down and
precaution can result in parts damage and/ cyclic stick full aft, check clearance
or equipment failure. between the aft longitudinal bellcrank
and the mast base. Minimum clearance
is 0.030 inch (0.762 mm). Adjust
(18). If necessary, adjust rod end of lateral longitudinal control rod (preferably) or
pitch control rod to meet limits speci- collective control rod as required.
fied in steps (12). and (13). above. When (25). With collective stick full up and cyclic
adjustment is complete, tighten jamnut stick full forward and full left, check
and make certain that length of control clearance between rotating swashplate
rod does not change. and scissors fitting. Also check clear-
ance between scissors rotating link and
lower hub shoe. Minimum clearance in
(19). Reconnect control rod to lateral bell- both cases is 0.030 inch (0.762 mm).
crank. Rotate hub 360 degrees to determine
location of minimum clearance. Adjust
collective control rod as required.
(20). Loosen friction control, friction knob,
knurled thumbnuts and hooks of (26). Repeat step (21). above with collective
rigging fixture and remove all three stick full up and cyclic stick full forward
fixtures. and full right.
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MAINTENANCE MANUAL
(27). With collective stick full up and cyclic (2). Use lateral rigging fixture (ST507) on
stick full aft and full left, check clear- forward side of lateral friction guide,
ance between scissors link and edge of with fixture cutout positioned over
pocket in rotating swashplate. Mini- friction knob stud (view C). Secure
mum clearance is 0.006 inch (0.1524 fixture hook in lower inboard end of
mm). Rotate hub 360 degrees to slot, tighten knurled thumbnut to seat
determine location of minimum clear- bushing at upper outboard end and
ance. Repeat clearance check with tighten lateral friction knob.
cyclic stick full aft and full right.
8. Cyclic Controls Rigging (L/H Command)
(28). Repeat steps (17). thru (22). above to (600N)
recheck all clearances.
(Ref. Figure 502)
(29). Repeat steps (7). of Collective Controls
Rigging, step (4)., and steps (9). thru Special Tools
(15). of Cyclic Controls Rigging, to (Ref. Section 910000)
recheck mixer control motion travels Item Nomenclature
and see that minimums are met.
(30). Install main rotor blades or remove (LH command)
supports and simultaneously lower all ST503 Mixer rigging plate
five blades to normal position. ST504 Longitudinal rigging fixture
(LH command)
(31). Track main rotor blades and adjust ST506 Lateral rigging fixture
autorotation rpm (Ref. Sec. 181000). (LH command)
7. Cyclic Controls Rigging (R/H Command)

(369D/E/FF 500N) NOTE: All cyclic control rigging is done with
collective stick on rigging fixture.
(Ref. Figure 501 and Figure 503) Rigging of (1). Remove main rotor blades, or manually
cyclic controls for the R/H command helicopter raise blades off droop stops by simulta-
is accomplished according to instructions for neously lifting blade tips. All six blades
L/H command helicopters except as follows: must be off stops during rigging.
Padded supports should be used.
Special Tools
(2). Release friction and raise pilots
collective stick. Position collective
Item Nomenclature
ST505 Longitudinal rigging fixture lower end of slot in collective friction
(RH command) guide link (view C).
(RH command) (3). Lower collective stick on rigging fixture
and tighten friction grip (drive gear).
(4). Adjust lateral cyclic trim for noload
(1). Use longitudinal rigging fixture
and install lateral cyclic rigging fixture
(ST505) on outboard side of longitudi-
(ST506).
nal friction guide, with fixture cutout
positioned over friction knob stud. (5). Position mixer rigging plate (ST503) on
Bushing end of fixture butts against mast support fitting.
upper end of slot in guide (Ref.
Figure 503, view B). Secure fixture (6). Check longitudinal travel as follows:
hook in lower end of slot, tighten
knurled thumbnut to seat bushing at NOTE: Adjust rod end, as required, to obtain
upper end, and tighten friction knob. the following limits.
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(a). With cyclic stick at forward stop, (369N2670). The minimum allowable
centerline of bolt in longitudinal clearance shall be 0.125 inch (3.175
bellcrank (369N2666) shall move up mm). Adjust collective control rod as
a minimum of 1.05 inches (26.67 mm) required.
above centerline of collective hinge
bolt. Reposition mixer plate to clear (13). With collective stick full up and cyclic
longitudinal bellcrank. stick full left (any position fore and aft),
check for interference between lateral
(b). With cyclic stick at aft stop, center- bellcrank (369N2670) and collective
line of bolt in bellcrank (369N2666) bellcrank (369N2664) of mixer controls.
shall move down a minimum of 0.65 When there is interference, lengthen
inch (16.51 mm) below centerline of lateral mixer control rod (369A7012) to
collective hinge bolt. maintain a minimum allowable clear-
ance of 0.030 inch (0.762 mm).
(7). Adjust longitudinal cyclic trim for
noload and install longitudinal cyclic (14). With collective stick full down and
rigging fixture (ST504). cyclic stick full aft, check clearance
between aft longitudinal bellcrank
(8). Remove lateral cyclic rigging fixture. (369N2668) and mast base. The
minimum allowable clearance shall be
(9). Check lateral travel as follows: 0.030 inch (0.762 mm). When clearance
is less than 0.030 inch (0.762 mm),
NOTE: Adjust rod end, as required, to obtain
adjust longitudinal control rod (prefera-
the following limits.
ble) or collective control rod.
(a). With cyclic stick at left stop, center- (15). With collective stick full up and cyclic
line of bolt head (fwd end) of bolt in stick full forward and full left, check
lateral bellcrank (369N2670) shall clearance between rotating swashplate
move down a minimum of 0.52 inch and scissors fitting. Also check clear-
(13.208 mm) below centerline of ance between scissors fitting and lower
collective hinge bolt. hub shoe. The minimum allowable
(b). With cyclic stick at right stop, clearance in both cases is 0.030 inch
centerline of bolthead in lateral (0.762 mm). Rotate hub 360 degrees to
bellcrank (369N2670) shall move up determine location of minimum clear-
a minimum of 0.37 inch (9.398 mm) ance. Adjust collective mixer control rod
above centerline of collective hinge as required.
bolt. (16). Repeat above step with collective stick
full up and cyclic stick full forward and
Do not adjust control rod beyond
full right.
ter final adjustment. Failure to observe this (17). With collective stick full up and cyclic
precaution can result in parts damage and/ stick full aft and full left, check clear-
or equipment failure. ance between scissors link and edge of
pocket in rotating swashplate. Rotate
(10). Set pitch change links at nominal 6.25 hub 360 degrees to determine location
inch (158.75 mm). of minimum clearance. Minimum
NOTE: Final adjustment of pitch change links clearance is 0.006 inch (0.152 mm).
will be accomplished during tracking and (18). Repeat clearance check with cyclic stick
autorotation rpm settings. full aft and full right.
(11). Remove all rigging fixtures. (19). Recheck all clearances from previous
steps.
(12). With collective stick full down and
cyclic stick forward and full left, check (20). Recheck control motion travels and
clearance between rotating swashplate check that minimum clearances are
and longitudinal pitch idler bellcrank met.
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MAINTENANCE MANUAL
(21). Install main rotor blades or remove (2). Remove backlash shims and gear shaft
supports and simultaneously lower all assembly from socket housing.
six blades to normal position.
NOTE: Note locations, mark and measure re-
(22). Track main rotor blades and adjust moved shim thicknesses to ensure reas-
autorotation rpm (Ref. Sec. 181000). sembly at same places.
9. Cyclic Controls Rigging (R/H Command) (3). Ensure that inboard collective pitch
(600N) stick socket internal gears are aligned
and mated. If gears are correctly
(Ref. Figure 502 and Figure 503) Rigging of aligned and mated, do not perform
cyclic controls for the R/H command helicopter steps (4). thru (6). and continue with
is accomplished according to instructions for step (7). If gears are misaligned,
L/H command helicopters except as follows: perform steps (4). thru (6).
(4). Disconnect link from idler and remove
Special Tools link and bellcrank as an assembly from
(Ref. Section 910000) gearshaft of inboard collective pitch
Item Nomenclature stick socket by removing bolt, two
ST501 Collective rigging fixture washers and nut.
(LH command)
NOTE: During gear shaft rotation to establish
correct midposition for gearshaft and pin-
ST505 Longitudinal rigging fixture ion in next step, gearshaft cutout is seen
(RH command) through hole in rear of socket assembly
ST507 Lateral rigging fixture housing.
(RH command)
(5). Rotate end of gas producer interconnect
torque tube in pilots stick socket
(1). Use longitudinal rigging fixture housing until gear shafttoN1 pinion
(ST505) on outboard side of longitudi- gearmesh is at midtravel and N1
nal friction guide, with fixture cutout pinion gear wide toothspace is posi-
positioned over friction knob stud. tioned at approximately one oclock.
Bushing end of fixture butts against View pinion by looking aft into open
upper end of slot in guide). Secure end of collective stick socket.
fixture hook in lower end of slot, tighten
knurled thumbnut to seat bushing at (6). Attach inboard collective pitch stick
upper end, and tighten friction knob. socket bellcrank to gearshaft and link
to idler. Bellcrank attachment bolt
(2). Use lateral rigging fixture (ST507) on must be installed with head slightly
forward side of lateral friction guide, down and forward.
with fixture cutout positioned over
friction knob stud. Secure fixture hook NOTE: Inboard collective N1 pinion gear must
in lower inboard end of slot, tighten be held in correct position while steps (7).
knurled thumbnut to seat bushing at thru (9). below are performed. If available,
upper outboard end and tighten lateral optional copilots collective pitch stick can be
friction knob. used to hold gear in position by setting copi-
lots throttle grip attachment bolts at ap-
10. Gas Producer Linkage Adjustment proximately seven oclock (looking aft) be-
fore engaging stick and socket.
(Ref. Figure 504 and Figure 505) Adjust gas
producer linkage in installed collective pitch (7). With inboard collective pitch stick
stick(s) and/or inboard socket assembly as socket N1 pinion gear held at position
follows: described in step (5)., rotate pilots
collective pitch stick throttle grip to
(1). Remove cap and outboard bearing from midtravel position (grip attaching
pilots collective pitch stick housing. bolts approximately straight down).
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PINION GEAR MOUNTING DISTANCE

0.6990.709 IN. (17.754618.0086 MM)
PINION GEAR
PINION BEARING
GAS PRODUCER TORQUE TUBE SPLIT SHIMS

(NOTES 1, 3) BEARING
DRIVEN GEAR
BEARING
BACKLASH SHIM(S) TOP VIEW HOUSING CAP

(NOTES 2, 3)
GENERAL NOTE:
SHIM SELECTED AS REQUIRED. 6 IDLE STOP
STEEL SHIMS PROVIDED IN 0.001, 0.002, GRIP MIDTRAVEL
0.005, 0.012 AND 0.032 IN.
((0.025, 0.051,
0.127, 0.305, 0.813 MM) THICKNESS.
N1 CLOSED
N1 OPEN
15
70 40 15
73 30 2 50
(NOTE 5)
CENTERLINE OF GAS
PRODUCER TORQUE TUBE
(NOTE 4)
CUTOUT IN
DRIVEN GEAR
LEFT SIDE VIEW
NOTES:
1. DETERMINES GEAR MOUNTING DISTANCE.
2. DETERMINES GEAR BACKLASH MAXIMUM 0.003 IN. (0.0762 MM).
3. SELECTED AS REQUIRED; STEEL SHIMS AVAILABLE IN 0.001, 0.002, 0.005,
0.0012 AND 0.032 IN. (0.025, 0.051, 0.127, 0.305, 0.813 MM) THICKNESSES.
4. ALSO CENTERLINE OF PINION GEAR AND CUTOUT IN DRIVEN GEAR.
5. CENTERLINE OF CENTER TOOTH ON DRIVEN GEAR.
G671014B
Figure 504. Gas Producer Drive Backlash Adjustment (Outboard Collective Stick)
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Revision 36 671000
MAINTENANCE MANUAL
NOTE:
SHIM SELECTED AS REQUIRED.
STEEL SHIMS PROVIDED IN 0.001, 0.002,
0.005, 0.012 AND 0.032 IN. ((0.025, 0.051,
0.127, 0.305, 0.813 MM) THICKNESS.
AFT BEARING LOCK RING

LOCK RING
FORWARD BEARING
2 50
15
70 40
73 30 15
6 IDLE STOP
N1 OPEN N1 CLOSED
(R/H COMMAND)
GRIP/N1 PINION GEAR N1 CLOSED
MIDTRAVEL (L/H COMMAND)
ROTATED 90 DEGREES
(LINK AND IDLER REMOVED FOR CLARITY)
IDLER
BELLCRANK
LINK
BEARING
WIDE TOOTHSPACE
ON SPLINE
BACKLASH SHIM(S)
(SEE NOTE) BEARING
LOOKING DOWN
G671023A
Figure 505. Gas Producer Drive Backlash Adjustment (Inboard Collective Stick)
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MAINTENANCE MANUAL
(8). Install backlash shims and gear shaft (6). Reinstall bolt to secure bellcrank to
in pilots collective stick socket housing. inboard gearshaft.
Ensure that gearshaft and pinion are
aligned and mated when pilots throttle (7). Reinstall snap plug in exterior skin.
grip is at midtravel.
(8). Reinstall pilot seat cover.
NOTE: Make sure that shims are installed in
original locations. NOTE: If optional dual controls are installed,
perform following rigging and deceleration
(9). Reinstall outboard bearing and cap on checks using copilot throttle.
pilots stick housing.
(9). Check engine gas producer controls
(10). Check that both pilots throttle grip and rigging (Ref. Chap. 76).
inboard collective pitch stick socket N1
pinion gear wide toothspace are correct (10). Perform deceleration check (Ref. Pilots
at midtravel. Flight Manual).
(11). Remove snap plug from skin, rotate 12. Gas Producer Interconnecting Torque
pilots throttle grip and visually check Tube Assembly Shimming (0003D thru
for evidence of backlash between gas 0929D)
producer interconnect torque tube and
hexagonal interior surfaces of gear- (Ref. Figure 506)
shaft. If necessary, remove cover and
gearshaft from torque tube and elimi- (1). Remove pilots seat cover and access
nate any backlash by tightening pipe door.
plug in end of torque tube. Zero back-
lash is required at both ends of tube. (2). Make an index mark on end of collec-
Reinstall snap plug. tive torque tube fitting flush with
inboard end of pilots collective stick
11. Pipe Plug Adjustment assembly housing using a felt pen or
pencil. Do not scribe index mark on
(Ref. Figure 407) fitting.
(1). Remove pilot seat cover for access to (3). Remove four bolts securing pilots
under seat controls. collective stick assembly to end of
(2). Remove snap plug from exterior skin. collective torque tube fitting.
(3). Remove bolt securing bellcrank to (4). Loosen pipe plug in end of gas producer
inboard gearshaft. interconnecting torque tube which
secures it to gas producer gearshaft in
(4). Position throttle midway between idle pilots collective stick assembly.
stop and full open.
(5). Remove pilots collective stick assembly.
(5). With assistant, tighten pipe plugs at
each end of torque tube simultaneously; (6). Using rubber mallet or equivalent soft
maintain throttle as set in step (4). tool, tap gas producer interconnecting
Initial torque required to turn pipe torque tube assembly toward copilots
plugs may be high because of dried zinc collective socket assembly. Avoid
chromate primer used at installation. damage to gas producer interconnecting
torque tube hex end or pipe plug
NOTE: If the normally installed plug does not threads.
sufficiently expand tube, a 1/827 internal
wrenching pipe plug 0.380 inch (9.652 mm) (7). Measure distance between index mark
long may be substituted. Whichever plug is on collective torque tube fitting and hex
used, it must not protrude more than 0.030 end of gas producer interconnecting
inch (0.762 mm) when tightened. torque tube.
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369H7352 PILOTS COLLECTIVE

CONTROL STICK ASSEMBLY
INDEX MARK OR LINE ON GAS
PRODUCER INTERCONNECTING
TORQUE TUBE END FITTING FLUSH
WITH THE INBOARD END OF THE
PILOTS COLLECTIVE STICK ASSEMBLY
GAS PRODUCER
INTERCONNECTING
TORQUE TUBE FITTING
INDEX MARKING
MEASUREMENT BETWEEN INDEX MARK

AND HEX END OF GAS PRODUCER
INTERCONNECTING TORQUE TUBE
HEX END
INDEX MARK
369H7355 GAS PRODUCER

INTERCONNECTING TORQUE
TUBE END FITTING
GAS PRODUCER INTERCONNECTING TORQUE TUBE MEASUREMENT
G6710151
Figure 506. Gas Producer Interconnecting Torque Tube Shimming Procedure

(0003D thru 0929D) (Sheet 1 of 2)
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MEASUREMENT BETWEEN INBOARD END OF PILOTS

COLLECTIVE STICK HOUSING AND END OF GEAR
SHAFT IN PILOTS COLLECTIVE STICK ASSEMBLY
PILOTS COLLECTIVE STICK

HOUSING ASSEMBLY
GEAR SHAFT IN PILOTS

COLLECTIVE STICK ASSEMBLY
GEAR SHAFT RECESSION MEASUREMENT
TOTAL THICKNESS OF AN960C816 WASHERS AND SNAP RING.

EQUAL TO 0.750 IN. (19.05 MM) MINUS ENGAGEMENT LENGTH OF
GAS PRODUCER INTERCONNECTING TORQUE TUBE INTO GEAR
SHAFT IN PILOTS COLLECTIVE STICK ASSEMBLY ADDED TO
END OF GAS PRODUCER INTERCONNECTING TORQUE TUBE.
ENGAGEMENT LENGTH OF GAS PRODUCER

INTERCONNECTING TORQUE TUBE INTO GEARSHAFT
OF PILOTS COLLECTIVE STICK ASSEMBLY.
0.750 IN. (19.05 MM) LENGTH OF HEX END ON

THE GAS PRODUCER INTERCONNECTING
TORQUE TUBE.
TORQUE TUBE SHIMMING
G6710152
Figure 506 Gas Producer Interconnecting Torque Tube Shimming Procedure

(0003D thru 0929D) (Sheet 2 of 2)
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(8). Measure distance between inboard end al rotation of drive gear grip and cause ny-
of pilots collective stick assembly lon gears to be stripped.
housing and inboard face of gas produc-
er gearshaft in pilots collective stick (1). Remove friction mechanism guard.
assembly.
(2). Rotate friction drive gear counterclock-
(9). Subtract measurement taken in step wise to maximum friction position.
(8). from measurement taken in step
(7). Remainder is engagement of gas (3). Remove cotter pin, nut, retainer
producer interconnecting torque tube assembly, teflon washer and one
with gearshaft in pilots collective stick phenolic washer.
assembly.
(4). Slide gear assembly out far enough to
(10). Subtract engagement (remainder) from disengage it from idler gear. Use care to
0.750 inch (19.05 mm). In addition to keep other washers and spacer from
thickness of external snap ring, add PN dropping.
AN960C816 washers to end of gas
producer interconnecting torque tube to (5). Remesh gear assembly with idler gear
a total thickness equal to the remainder to position pin on peak of cam. Check
from 0.750 inch (19.05 mm) less that drive gear is still at maximum
engagement. Equivalent washers in friction stop position.
varying thicknesses may be in combina-
tion with PN AN960C816 washers. (6). If gear assembly does not correctly
position pin, reposition idler gear on
(11). Reinstall pilots collective stick assem- drive gear.
bly.
NOTE: Ratio of idler gear to gear assembly is
(12). Tighten pipe plug of gas producer 3:1, which permits fine adjustment. When
interconnecting torque tube to obtain repositioning idler gear, be sure to reinstall
zero backlash between torque tube and same number of washers that were removed
gearshaft in pilots collective stick from between cotter pin and idler. These
assembly. washers limit gear end play to maximum of
0.010 inch (0.254 mm). When reassembled,
(13). Reinstall pilots seat cover and access gear train must rotate freely.
door.
(7). Reinstall phenolic washer, teflon
washer, retainer assembly and nut.
13. Collective Stick Friction Mechanism
Adjustment (8). With drive gear still at maximum
friction position, tighten retainer nut
(Ref. Figure 507) until it just bottoms on retainer stop.
For collective friction mecha- (9). Rotate friction drive gear clockwise to
CAUTION nism to be correctly adjusted for minimum friction stop position, release
maximum friction, three actions must occur grip and perform checks in steps (10).
at same time: Drive gear must contact stick and (11). below.
fitting fixed stop; spring retainer housing
washer must contact retainer internal stop; (10). If pin has overridden low point of cam
and gear assembly pin must be at approxi- (desired minimum friction position),
mate peak of cam. Do not overtighten re- and griptostick friction prevents
tainer nut so that retainer washer contacts springback of pin to cam low point, turn
retainer stop before friction drive gear grip and move pin to low point.
reaches stick fitting stop. Adjustment that
does not produce approximately simulta- NOTE: A drive gear that does not rotate freely
neous contact will allow excessive addition- on collective stick tube should be replaced.
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GUARD
WASHER(S)
STICK FITTING
(NOTE 1)
COTTER
FRICTION
PIN
DRIVE GEAR
PHENOLIC WASHERS (ROTATING
TEFLON STOP)
WASHER
RETAINER HOUSING
COTTER PIN MAXIMUM
IDLER FRICTION
GEAR NUT
STICK FITTING
(FIXED STOP)
FRICTION CONTROL
DRIVEN WASHER
GEAR STOP SPRING
GEAR SPACER
ASSEMBLY
GUIDE
(NOTE 2) CAM
ALUMINUM
WASHER
GUARD
FRICTION MECHANISM ATTACHMENT
NYLON STRAP
GEAR ASSEMBLY PIN
(NOTE 4)
NOTE 3 NOTE 5
NOTE 6
NOTES: CAM ACTION

1. SHIMMED AS REQUIRED FOR 0.010 IN. (0.254 MM) MAXIMUM
END PLAY. GEAR TRAIN MUST ROTATE FREELY.
2. GEAR ASSEMBLY MUST SLIDE AND ROTATE FREELY IN FITTING.
GREASE APPLIED TO SHAFT.
3. ACCEPTABLE MINIMUM FRICTION POSITION.
4. DESIRED MINIMUM FRICTION POSITION (CAM LOW POINT).
G671016B
5. CORRECT MAXIMUM FRICTION POSITION (CAM HIGH POINT).
6. UNACCEPTABLE MAXIMUM FRICTION POSITION.
Figure 507. Collective Stick Friction Adjustment
Page 522
Revision 36 671000
MAINTENANCE MANUAL
(11). With pin on cam low point, rotate (2). Prior to test flight, establish halfway
retainer assembly. It should turn freely point of collective friction adjustment
on shaft of gear assembly with only grip (drive gear) as follows.
light finger pressure. Adjust retainer
nut to nearest castellation that pro- (a). Using soft, colored pencil; index
duces zero friction (no drag on retainer collective friction adjustment grip at
assembly during rotation). Install cotter zero friction.
pin.
(b). Roll on maximum friction (approxi-
NOTE: If undesirable collective forces ("light", mately 275 degrees rotation). Note
"heavy" or "creeping") are reported to exist travel and reset friction grip half
in collective stick during flight, do not at- way; hold in this position.
tempt to compensate by an increase in col-
lective friction. Condition should be cor- (c). Using dot of white paint or similar
rected elsewhere in control system (Ref. method, temporarily mark top of
Collective Controls Rigging (L/H Command) friction grip and adjacent exposed
and Collective Bungee Adjustment). area of collective stick. Friction
halfway index mark should be
14. Collective Bungee Adjustment visible to pilot.
(Ref. Figure 404) Adjustment of bungee system (3). While helicopter is on ground, adjust
is only permissible when helicopter is on bungee to extent necessary to avoid any
ground. upload in flat pitch at normal rpm. This
adjustment must also provide absence
of an excessive download or upload
WARNING while in hover and at 120 knots level
cruise. Helicopter must be landed after
D Do not attempt bungee adjustment in each flight check, before making
flight, control jamming can result. corrective adjustment.
D Use all necessary precautions to pre-
vent possible entry of any foreign ob- CAUTION
jects into controls linkage exposed
by removal of pilots seat cover to D After each bungee adjustment is made,
make adjustment of bungee system. collective stick must be slowly moved
Do not attempt bungee adjustment in through its full travel range to assure
flight, control jamming could result. that there is no binding or restriction of
stick motion, and that spring does not bot-
(1). Collective load forces are affected by tom at overcenter position.
any adjustment made in main rotor
system. Comply with the following. D Do not turn female bearing assembly
spring retainer while bungee installation
(a). Bungee adjustment should be made tool is spring loaded.
only when main rotor blades are in D When making adjustments to the bungee
track and autorotation rpm is overcenter fitting, ensure nut turns
established. when bolt adjustment is made. Cotter pin
can be sheared if nut does not turn with
(b). Ensure that collective stick friction is bolt.
correctly adjusted.
(a). If an upload exists on ground at flat
(c). Perform flight evaluation of collective pitch and normal rpm but a down-
forces with helicopter takeoff weight load prevails during hover and at 120
at 2350 pounds (1066 kg), N2 at 103 knot level cruise, turn bungee
percent and zero collective stick adjustment retainer nut clockwise to
friction. increase preload in bungee system.
Page 523
671000 Revision 29
MAINTENANCE MANUAL
(b). To correct a download on ground During following tests, do not

during flat pitch at normal rpm and CAUTION retract spring assembly (ram) so
an upload condition during hover and that actuator length is less than 13.50 in-
120 knot level cruise, turn bungee ches (34.29 cm) between attach bolt centers.
adjustment retainer nut counter-
clockwise to decrease preload in (4). With actuator spring assembly (ram)
bungee system. approximately halfway between travel
limits (actuator length at 14.46 inches
(c). When a relatively constant upload (36.7284 cm) between attach bolt
condition prevails during flat pitch at centers), set up test dial indicator and
normal rpm on the ground, at hover, measure ram end play. End play must
and at 120 knot level cruise, decrease be within 0.0100.050 inch (0.2541.27
upload by turning bungee overcent- mm). While adjusting screw, check that
er adjustment bolt clockwise. there is threadlocking friction from
(d). When a relatively constant download selflocking threaded insert. If end play
condition prevails during flat pitch at is excessive, replace actuator.
normal rpm on the ground, at hover,
and at 120 knot level cruise, decrease NOTE:
download by turning bungee over D When power is applied to the 8222M6
center adjustment bolt counterclock- (369A7014) actuator, it will move in the
wise. commanded direction until it reaches the
end of the stroke. If, during midtravel,
NOTE: Rotation of adjustment bolt head is the an opposite power is applied simulta-
only mechanical operation required to ad- neously, it will stop and remain stopped
just overcenter position of bungee fitting. until one or the other input is removed.
(e). After minimum and balanced collec- D When power is applied to the 8222M7
tive forces are obtained, not more (369D27001) actuator, it will move, as
than onehalf of available collective commanded, and like the M6, if power is
stick friction (friction grip at half applied simultaneously in the opposite di-
way index) must cancel collective rection, it will stop. Unlike the M6, when
forces during flight test at 140 knots one of the inputs is removed, the M7 ac-
level flight. tuator may or may not start. If it does not
(f). If friction applied in step (e). above is restart, it has been latched into the off
insufficient to cancel collective forces, state by the current surge generated upon
repeat adjustment procedure. applying the second input. The M7 has a
builtin current limit circuit that latches
15. Cyclic Trim Actuator Bench Testing it off if the actuator current exceeds 2.7
(369D/E/FF 500N) amp. All power must be removed in order
to unlatch it.
(Ref. Figure 508)
(5). Position test switch to RETRACT and
(1). Connect cyclic trim actuator to test allow actuator ram to retract to a
harness and equipment. length of 13.50 inches (34.29 cm)
(2). Mount actuator in suitable fixture that between attach bolt centers.
allows vertical extension and retrac-
tion. (6). Using stopwatch, check actuator ram
travel time from fully retracted to fully
(3). Turn on directcurrent power and extended. Check time interval for
adjust output to 25.75 26.25 volts. actuator motor tested.
Page 524
Revision 31 671000
MAINTENANCE MANUAL
NOTE: The times in the following charts are (0.508 mm) maximum with an overrid-
maximum times. Some actuators will travel ing (aiding) load; otherwise there must
at a greater speed than others. Intervals of be no overtravel.
less time are acceptable.
(12). Remove 163 pound (74 kg) load and
repeat step (4). above.
Actuator Motor Time Interval
Part number (Seconds) (13). Run actuator until arm is extended 1.75
inches (4.445 cm). Turn power off and
369A7001 58.4 disconnect cyclic trim actuator.
369A7014 (High Speed) 38.0 16. Cyclic Trim Actuator Bench Testing (600N)
369D27001 (Super Fast) 17.5 (Ref. Figure 508)
(7). Measure length of extended ram. (1). Connect cyclic trim actuator to test
Subtract measured result of step (5). harness and equipment.
above from this value. Result must be (2). Mount actuator in suitable fixture that
1.92 inches (4.8768 cm) minimum. allows vertical extension and retrac-
tion.
Do not run actuator against ex-
CAUTION tend limit stop with the (3). Turn on directcurrent power and
163pound weight aiding actuation. Actua- adjust output to 25.75 26.25 volts.
tor thrust bearing may be damaged. During following tests, do not
CAUTION retract spring assembly (ram) so
(8). Connect a 163 pound (74 kg) load to
actuator. Set switch at RETRACT. that actuator length is less than 13.50 in-
Check time it takes ram to travel ches between attach bolt centers.
1.721.78 inches (4.36884.5212 cm) to (4). With actuator spring assembly (ram)
retract stop. Check retraction time for approximately halfway between travel
actuator motor tested. limits (actuator length at 14.46 inches
(36.7284 cm) between attach bolt
Actuator Motor Time Interval centers), set up test dial indicator and
Part number (Seconds) measure ram end play. End play must
be within 0.0100.050 inch (0.2541.27
369A7001 3050 mm). While adjusting screw, check that
369A7014 (High Speed) 1525 there is threadlocking friction from
selflocking threaded insert. If end play
369D27001 (Super Fast) 712 is excessive, replace actuator.
(9). Operating current under load condi- NOTE: When power is applied to the 8222M21
tions must not exceed 1.2 amperes (600N7001) actuator, it will move, as com-
running and 2.0 amperes stalled. manded, and if power is applied simulta-
neously in the opposite direction, it will
(10). Reduce voltage input to 21 volts. stop. When one of the inputs is removed, the
Actuator ram must retract and extend. actuator may or may not start. If it does not
Overtravel is limited to 0.020 inch restart, it has been latched into the off state
(0.508 mm) with an overriding (aiding) by the current surge generated upon apply-
load; otherwise there must be no ing the second input. The actuator has a
overtravel. builtin current limit circuit that latches it
off if the actuator current exceeds 3.1 amp.
NOTE: It is not necessary to extend or retract All power must be removed in order to un-
actuator ram more than 1/4 inch (6.35 mm) latch it.
for test in steps (10). above or (11). below.
(5). Position test switch to RETRACT and
(11). Increase input voltage to 28 volts. allow actuator ram to retract to a
Actuator arm must retract and extend. length of 13.50 inches (34.29 cm)
Overtravel is limited to 0.020 inch between attach bolt centers.
Page 525
671000 Revision 36
MAINTENANCE MANUAL
(6). Using stopwatch, check actuator ram Actuator Motor Time Interval
travel time from fully retracted to fully Part number (Seconds)
extended. Check time interval for
actuator motor tested. 600N70011 (longitudinal) 712
NOTE: The time in the following chart is maxi- 369D270013 (lateral) 712
mum time. Some actuators will travel at a 600N70141 (lateral, with 712
greater speed than others. Intervals of less YSAS)
time are acceptable.
(9). Operating current under load condi-
Actuator Motor Time Interval tions must not exceed 1.2 amperes
Part number (Seconds) running and 2.0 amperes stalled.
600N70011 (longitudinal) 6.6 (10). Reduce voltage input to 21 volts.
Actuator ram must retract and extend.
369D270013 (lateral) 11.0 Overtravel is limited to 0.020 inch
600N70141 (lateral, with 11.0 (0.508 mm) with an overriding (aiding)
YSAS) load; otherwise there must be no
overtravel.
(7). Measure length of extended ram. NOTE: It is not necessary to extend or retract
Subtract measured result of step (5). actuator ram more than 1/4 inch (6.35 mm)
above from this value. Result must be for test in steps (10). above or (11). below.
1.92 inches (4.8768 cm).
(11). Increase input voltage to 28 volts.
Do not run actuator against ex- Actuator arm must retract and extend.
CAUTION tend limit stop with the Overtravel is limited to 0.020 inch
163pound weight aiding actuation. Actua- (0.508 mm) maximum with an overrid-
tor thrust bearing may be damaged. ing (aiding) load; otherwise there must
be no overtravel.
(8). Connect a 163 pound (74 kg) load to (12). Remove 163 pound (74 kg) load and
actuator. Set switch at RETRACT. repeat step (4). above.
Check time it takes ram to travel
1.721.78 inches (4.36884.5212 cm) to (13). Run actuator until arm is extended 1.75
retract stop. Check retraction time for inches (4.445 cm). Turn power off and
actuator motor tested. disconnect cyclic trim actuator.
Page 526
Revision 36 671000
MAINTENANCE MANUAL
SPRING
ADAPTER
SPRING GUIDE
SPRING ADAPTER SCREW TEST LOAD

CONNECTION
ADAPTER
TRIM TUBE
ACTUATOR TRIM DECAL
SELFLOCKING THREAD INSERT
SPRING
NOTE WASHER
ACTUATOR
RIVET
(4 PLCS)
SPRING PIN
ACTUATOR HOUSING TRIM TUBE
ADAPTER
ACTUATOR
ACTUATOR TUBE PIN INSTALLATION
1.00 IN.
HOUSING HOLE
(2.54 CM)
NOTE: REPLACEMENT PARTS HAVE NUTPLATE
RIVETED IN PLACE. WASHER, NUT AND COTTER PIN NOT
REQUIRED. TRIM TUBE INSTALLATION
ITEM TEST EQUIPMENT

NO. SPDT SWITCH
1 STOPWATCH, MARKED IN M1 EXTEND

A
1/10SECOND
INCREMENTS (MINERVA OR MA OFF
26 VDC B
EQUIVALENT). ELECTRICAL V M2 RETRACT
POWER
2 6 IN. (15.25 CM) SCALE. SOURCE C
3 DC VOLTMETER, 050 VOLTS
TEST HOOKUP CONNECTOR
(WESTON
MODEL 931 OR EQUIVALENT).
4 DC MILLIAMMETER, 05 AMPERES
(WESTON
5 VARIABLE DC POWER SUPPLY, G671017B

1036 VOLTS
(N.J.E. MODEL SY 3610 OR
EQUIVALENT). Figure 508. Cyclic Trim Actuator Assembly
6 DIAL INDICATOR GAGE (BROWN
AND SHARP,
Page 527
7 SWITCH, SPDT: CENTER OFF.

671000 Revision 21
MAINTENANCE MANUAL
P9J
TB12
CB102 TRIM
1 5A 2 P A
CYCLIC TRIM P130J J109

S B S
UP
TB13
L R
V RED B RED V
LAT
P106
TRIM
DN MOTOR A RED A
S107
B102 B BLU C BLU R
E6
R BLU D
TB19
A
TB11
U RED B U
LONG
P105
TRIM
MOTOR A RED A
B101 B BLU C
E25
C
X BLU D X
T E5 E7 T
LEFT CYCLIC RIGHT CYCLIC

STICK GRIP STICK GRIP
G671000
Figure 509. Cyclic Trim Wiring Diagram
Page 528
Revision 21 671000
MAINTENANCE MANUAL
P112
L90A16 D
INCR C110A20 E
S108 C108E20
RPM F
C109A20
TRIM H
DECR
A
COPILOTS COLLECTIVE B
STICK C SPARE PINS
J
K
WIRING DIAGRAM
N2 GOVERNOR SWITCH
(NOTE 1)
WIRE GUIDE
AWG SIZE 4
AWG SIZE 12 VINYL TUBING
VINYL TUBING (NOTE 3)
(NOTE 2)
AWG SIZE 4
VINYL TUBING
NYLON STRAP
GROUND TERMINAL NOTES:
1. DISCARD 29761 LOCKING RING BEFORE
INSTALLING SWITCH.
2. ENCASE EACH WIRE FULL LENGTH WITH AWG
SIZE 12 VINYL TUBING.
3. AWG SIZE 4 TUBING SHOULD NOT EXTEND INSIDE
CONTROL STICK MORE THAN 0.060 IN. (1.524 MM).
4. WRAP WIRE BUNDLE WITH CT93C TAPE AS
AWG SIZE 8 REQUIRED.
TAPE
VINYL TUBING ROTATED
(NOTE 4)
CABLE ROUTING
G671018A
Figure 510. Wiring Diagram and Cable Routing (Collective Stick)
Page 529
671000 Revision 21
MAINTENANCE MANUAL
ICS
1 W
S112 2 T
RADIO 3 P WIRE BUNDLE
SW THRU STICK
XMT
RT 7 V
DW 5 U
S107 S
6 CYCLIC CONTROL
CYCLIC R WIRE BUNDLE
LEFT 4 STICK GRIP
TRIM X THRU STICK
UP 8
B
A
H AWG SIZE 3
J VINYL TUBING
K (NOTE 1)
N
UNUSED PINS M
L
E
D
C
F
WIRING DIAGRAM
AWG SIZE 3
VINYL TUBING
(NOTE 1)
CYCLIC CONTROL STICK

NYLON STRAP
LOCATION OPTIONAL
AWG SIZE 0
VINYL TUBING
(NOTE 2)
NOTES:
1. WIRES FURNISHED WITH GRIP. SPLIT INTO TWO
EQUAL BUNDLES AND RUN EACH BUNDLE THRU
HOLES AS SHOWN. ENCASE EACH BUNDLE IN
AWG SIZE 3 VINYL TUBING.
2. ENCASE TWO BUNDLES IN AWG SIZE 0 VINYL
TUBING. END OF BUNDLE LOCATION IS
OPTIONAL. TAPE END OF TUBING WITH CT93C
TAPE AS REQUIRED.
CABLE ROUTING
G671019
Figure 511. Wiring Diagram and Cable Routing (Cyclic Stick)
Page 530
Revision 21 671000
MAINTENANCE MANUAL

INSPECTION/CHECK
1. TunnelRouted Control Rod Inspection (c). Lightly deflect tube laterally from
one extreme to other (maintain
(Ref. Figure 601) preload).
(1). Inspect rod end bearings for binding (d). With dial indicator or 6 inch (15.25
and excessive wear, 0.040 inch (1.016 cm) rule, measure total horizontal
mm) maximum axial play. movement at top of tube where rod
end enters.
(2). Inspect control rod for surface damage
and evidence of bending. (e). If total movement exceeds 1/16 inch
(1.5875 mm) rod assembly must be
(3). Inspect upper two inches (5.08 cm) of replaced with serviceable parts.
each tunnel routed control rod for wear.
Replace rods with wear depth exceeding (f). Movement less than 3/64 inch
0.020 inch (0.508 mm), or having outer (1.190625 mm) is considered negligi-
diameter (OD) less than minimum ble.
which follow.
(g). If movement is between 3/64 and 1/16
inch (1.5875 and 1.190625 mm),
Minimum OD
inspect rod threads, step (6)., or rod
Control Rod Inches (mm)
insert, step (7).
Collective mixer 0.470 (11.938)
(6). For early control tubes without swaged
Longitudinal mixer 0.520 (13.208) inserts:
Lateral mixer 0.530 (13.462) (a). If total lateral movement of upper
end of tube is found to be between
Tail rotor 0.470 (11.938)) 3/64 and 1/16 inch (1.5875 and
1.190625 mm), check rod threads.
(4). Inspect for loose rivet at fixed rod end
(lower end). (b). Disconnect rod end from control
system.
CAUTION (c). Screw rod end completely out of
control rod.
D When tightening loosened jam nuts on
rod ends as in steps (5). and (6). or (7). be- (d). Use 0.339 inch (8.6106 mm) diameter
low, always hold rod end with wrench. drill (size R), free of burrs, to check
D Do not disconnect rod ends from mixer as- rod threads.
sembly to perform this inspection except
1). If drill can be inserted, rod assem-
as instructed.
bly is unserviceable and must be
(5). Inspect upper end of tunnelrouted replaced.
control rod assemblies for excessive rod 2). If drill cannot be inserted, rod is
end play. serviceable.
(a). Loosen jam nut minimum of two (e). Reinstall rod end, reconnect rod to
threads. control system and tighten jam nut.
(b). Preload rod end against either side of (7). For current control rods with swaged
attaching clevis with light finger inserts:
pressure to eliminate play other than
in area being inspected and effect of (a). Disconnect rod end from control
bearing play. system.
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671000 Revision 28
MAINTENANCE MANUAL
LONGITUDINAL PITCH IDLER
COLLECTIVE PITCH MIXER BELLCRANK
LONGITUDINAL MIXER
CONTROL ROD
COLLECTIVE MIXER
CONTROL ROD
LATERAL BELLCRANK
TAIL ROTOR CONTROL ROD
LATERAL MIXER CONTROL ROD
INITIAL ROD LENGTH (BEFORE RIG)
DIM L
CONTROL ROD INCH (CM)
LONGITUDINAL MIXER 56.67 (

143.9418)
LATERAL MIXER 56.51 (
COLLECTIVE PITCH FITTING
143.5354)
COLLECTIVE MIXER
55.67 (
141.4018) 2.00 IN. (5.08 CM)
RIVET
(NOTE)
53.14 (
134.9756)
L
MAXIMUM ALLOWABLE AXIAL

PLAY 0.040 IN. (1.016 MM)
CONTROLS
SUPPORT BRACKET
LONGITUDINAL IDLER
BELLCRANK
LATERAL IDLER BELLCRANK
NOTE:
INSPECT FOR WEAR. REPLACE RODS WITH WEAR
DEPTH EXCEEDING 0.020 IN. (0.508 MM) OR HAVING
OD LESS THAN ALLOWABLE MINIMUM.
G671020A
Figure 601. TunnelRouted Control Rod Inspection
Page 602
Revision 21 671000
MAINTENANCE MANUAL
(b). Back off jam nut sufficiently enough NOTE: Pitch stick housing and cap may be ei-
to inspect insert. ther magnesium or alloy casting. (For corro-
sion control and identification of magne-
(c). Inspect insert for proper installation, sium or aluminum alloys, Ref. Sec.
flush to a maximum of 0.010 inch 204000.)
(0.254 mm) below the surface of the
rod. 4. Copilots Collective Pitch Stick Inspection
(d). Check that insert is tight inside of (Ref. Figure 603)
rod.
(1). Inspect bearings for binding or play.
1). If insert is loose or protrudes above
surface of rod, rod assembly is (2). Inspect all gears for cracks, and
unserviceable and must be repla- chipped or broken teeth.
ced.
(3). Inspect stick tube and gas producer
2). If insert is tight and swaged flush control tube for corrosion, deformation
to 0.010 inch (0.254 mm) below the and loose rivets.
surface of the rod, rod is servi-
ceable.
5. Collective Stick Friction Mechanism
(e). Reconnect rod to control system and Operational Check
tighten jam nut.
(Ref. Figure 602)
(8). Check rigging of reconnected control
system. (1). Remove guard from collective stick.
(2). Check that teeth of friction drive gear,

2. Controls Support Bracket and Bellcrank
idler gear, and driven gear are not
Inspection
stripped or otherwise damaged.
(Ref. Figure 403)
(3). Rotate friction drive gear grip counter-
(1). Inspect bearings in bellcranks for clockwise to maximum friction stop;
binding. gear train must rotate freely. Check
position of shaft assembly pin. Pin
(2). Perform fluorescent dye penetrant should be at highest point of cam.
inspection on any suspected part.
(4). If pin is not at approximate peak of cam
NOTE: Parts identified with double asterisk or has overridden peak, friction mecha-
(**) (Ref. Figure 403) may be either magne- nism must be readjusted. If pin is in
sium or aluminum alloy. (For corrosion con- correct position, continue with step (5).
trol and identification of magnesium and below.
aluminum alloys, Ref. Sec. 204000.)
(5). Rotate drive gear grip clockwise to
3. Pilots Collective Pitch Stick Inspection minimum friction position and release
grip; gear train must rotate freely. Pin
(Ref. Figure 602) should be at approximate low point of
cam.
(1). Inspect bearings for binding or play.
(6). With pin on low point of cam, hand
(2). Inspect all gears for cracks, and rotate spring release housing. If there is
chipped or broken teeth. drag on retainer, there is friction on
guide and collective friction must be
(3). Inspect stick tube and gas producer readjusted. If retainer rotates freely,
control tube for corrosion, deformation without obvious play, low point friction
and loose rivets. setting is correct.
Page 603
671000 Revision 28
MAINTENANCE MANUAL
FRICTION WASHER
(FELT)
BACKUP DISC
THROTTLE GRIP (METAL)
(NOTE 1) THROTTLE FRICTION
MOUNTING DISTANCE
SWITCH HOUSING NUT (NOTE 1)
SHIM (CUT)
FRICTION DISC (NYLON) COVER
BEARING
SPRING BACKUP DISC (METAL) (NOTE 3)
GRIP ATTACH BOLTS

GAS PRODUCER
CONTROL TUBE
IDLE STOP RELEASE RING PINION
HOUSING SOCKET (NOTE 1)
NYLON STRAP FITTING
SETSCREW (NOTE 1)
(NOTE 5) SHIM WASHER
SETSCREW IDLER GEAR
BEARING BACKLASH
STICK NYLON (NOTE 3) SHIM GEARSHAFT
GUARD FITTING STRAP BACKLASH SHIM
BEARING
(NOTE 3)
NYLON STRAP
GEAR CAP
(NOTE 1) PHENOLIC WASHERS
CAM
(NOTE 1) (NOTE 2) FRICTION ADJUSTMENT
TEFLON WASHER
STICK TUBE
WIRE GUIDE
SPACER
NOTE 1
FRICTION (NOTE 1) RETAINER
DRIVE GEAR
GUIDE
(NOTE 4)
SETSCREW
NOTES:
1. SURFACES IN CONTACT DURING ROTATION, OR OTHERWISE
NOTED, TO BE LUBRICATED WITH GREASE.
2. NEW PHENOLIC WASHERS ABRADED TO REMOVE GLAZE.
3. BEARINGS INSTALLED WITH GRADE A LOCKING COMPOUND
AFTER SHIMMING.
4. DRIVE GEAR END PLAY 0.0020.010 IN. (0.05080.254 MM).
5. USED ONLY WITH OPTIONAL EQUIPMENT.
G671021B
Figure 602. Outboard Collective Stick Inspection (L/H Command)
Page 604
Revision 39 671000
MAINTENANCE MANUAL
MOUNTING DISTANCE SHIM

(CUT)
BEARING
(NOTE 2)
GAS PRODUCER CONTROL TUBE COVER
PINION
HOUSING SOCKET
(NOTE 1) BEARING
(NOTE 2)
BACKLASH SHIM
GEARSHAFT
NYLON STRAP BACKLASH SHIM
ELECTRICAL
WIRING
STICK TUBE BEARING

(NOTE 2)
NOTE 1 CONNECTOR CAP

PIN
SETSCREW
WIRE GUIDE
ADJUSTMENT NUT
SETSCREW
THROTTLE GRIP
GRIP ATTACH BOLT NOTES:

1. SURFACES IN CONTACT DURING ROTATION
TO BE LUBRICATED OR OTHERWISE NOTED,
WITH GREASE (CM116).
SETSCREW
2. INSTALL BEARINGS WITH GRADE A LOCKING
COMPOUND (CM431) AFTER SHIMMING FOR
SWITCH HOUSING MOUNTING DISTANCE AND BACKLASH.
44162B
Figure 603. Outboard Collective Stick Inspection (R/H Command)
Page 605
671000 Revision 21
MAINTENANCE MANUAL
6. Collective Control Interconnecting Torque NOTE: Bungee support bracket may be either
Tube Inspection an aluminum or magnesium casting. (For
corrosion control and identification of mag-
(Ref. Figure 404) nesium and aluminum alloys, Ref. Sec.
204000.)
(1). Remove pilots seat cover, control access 8. Inboard Collective Stick Socket Assembly
door, and left side foot support fairing. Inspection
(Ref. Figure 408)
(2). Inspect collective interconnecting
torque tube for cracks, bends or (1). Inspect all bearings for binding or play.
distortions. (2). Inspect gears for cracks, and chipped or
broken teeth.
(3). Inspect bungee bracket and bungee
fitting for security and condition. (3). Inspect all components for cracks,
Ensure cotter pin in overcenter corrosion and deformation.
adjustment bolt is not sheared. NOTE: Bellcrank and idler may be either an
aluminum or magnesium casting. (For cor-
(4). Inspect all accessible rivets for play. rosion control and identification of magne-
inspect support bearings for security sium and aluminum alloy parts, Ref. Sec.
and evidence of binding. 204000.)
(5). Reinstall pilots seat cover, controls 9. Pilots Cyclic Control Stick Inspection
access door and foot support fairing.
(Ref. Figure 604)
7. Collective Bungee Inspection NOTE:

D For this inspection, friction stop nut must
(Ref. Figure 407) be loosened.
D Socket may be either an aluminum or
NOTE: Replace any bungee parts in question- magnesium casting. (For corrosion con-
able condition. trol and identification of magnesium and
aluminum alloys, Ref. Sec. 204000.)
(1). Inspect bearings in male and female (1). Inspect stick tube attachment to socket
bearing assemblies for evidence of for evidence of loose rivets, distortion
binding, corrosion and galling. and corrosion.
(2). Inspect female bearing assembly (2). Inspect parts of friction mechanism for
threads for damage. physical damage. Free length of friction
spring should be approximately 0.580
inch (14.732 mm).
(3). Inspect spring for evidence of deforma-
tion. Free length of spring must be; (3). To check installation, loosen lateral and
longitudinal friction knobs, move cyclic
(a). Effectivity: 369D/E/FF500N, 3.64 control stick and check for binding or
0.06 inches (92.456 1.524 mm) unusual noises. Check that rod end
bearings of pilots lateral control rod do
(b). Effectivity: 600N, 4.50 0.025 inches not jam when stick is full forward and
(114.30 +0.635 mm) full aft.
NOTE: Set minimum friction so that phenolic
(4). Inspect male bearing rod for cracks, washers can be slightly turned by hand. If
evidence of binding, corrosion and minimum friction is set too low, stick shake
deformation. will occur.
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MAINTENANCE MANUAL
10. Copilots Cyclic Control Stick Inspection (5). Replace oneway lock if exposed portion
of piston has nicks, scratches or wear
(Ref. Figure 604) penetrates chrome plating.
Consumable Materials (6). Replace external mounting bushing if

(Ref. Section 910000) outside diameter is less than 0.4979
Item Nomenclature inch (12.64666 mm).
CM114 Petrolatum (7). Oneway lock must be replaced if nicks,
dents and scratches to body exceed
(1). Inspect quickrelease pins for secure 0.040 inch (1.016 mm) depth after
fit, also stick tube and socket for repair.
security, distortion and corrosion.
Check for presence of a light coating of (8). Oneway lock must be replaced if end
grease in socket and on stick tube end. play between rod ends exceeds 0.010
Apply thin coating of petrolatum inch (0.254 mm) measured at input
(CM114), on contact surfaces. (forward) end.
(2). To check controls installation, loosen (9). Oneway lock must be replaced if
lateral and longitudinal friction knobs, leaking, except as noted for reservoir in
move stick and check for binding or step (1). above.
unusual noises. Check that rod end
bearings of copilots lateral control rod 12. Cyclic Trim Actuator Inspection
do not jam throughout full range of
stick travel. (Ref. Figure 508)
NOTE: Set minimum friction so that phenolic (1). Inspect electrical connector for evidence
washers can be slightly turned by hand. If
of damage, and broken or missing
minimum friction is set too low, stick shake
contacts.
will occur.
(2). Inspect exterior of trim actuator for
11. OneWay Lock Inspection
evidence of damage and deformation.
(1). Replace reservoir if cracked, leaking or
has loose or damaged filler cap (Ref. (3). When actuator speed (response and/or
COM). travel time) is questionable, perform
bench test (Ref. Cyclic Trim Actuator
NOTE: It is normal for a thin hydraulic oil film Bench Test).
to remain on piston as a result of wiping
contact with the piston seal. This should not 13. Cyclic Control System Operational Check
be considered leakage or cause for rejection.
Excessive slack or free play in the cyclic
(2). Replace forward input rod end bearing control system may result in premature
if bearing binds. control stop contact or roughness of the
Do not attempt to adjust larger helicopter and fanning out (out of track) of the
CAUTION (aft) of two rod ends and do not main rotor tip path plane (Ref. Sec.
remove cotter pin; malfunction of lock will 181000/60). Areas to be checked include
likely result. (For overhaul and replacement mixer linkages (Ref. Sec. 623000/60) at the
instructions, Ref. COM). base of the main rotor mast, rotating controls
above the swashplate, trim actuators, and
(3). Replace oneway lock if aft (output) end cyclic control stick in the pilots compartment.
bearing binds. If total free play at the top of the cyclic grip
exceeds 3/8 inch (9.525 mm) in either longitu-
(4). Replace protective boot if it is cracked, dinal or lateral direction, perform the follow-
torn or deteriorated. ing:
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671000 Revision 39
MAINTENANCE MANUAL
SLEEVE BUSHING
NOTE 2
NOTE 2
LINK NOTES:
FRICTION 1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF
MECHANISM STUD * 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.060 IN. (1.524 MM)
ABOVE OUTSIDE SURFACE OF PART AFTER BOLT IS
TIGHTENED.
2. WASHERS ARRANGED TO ALIGN LINK WITH TORQUE
TUBE; LOOSELY SPACED WITH THREE WASHERS.
KNOB 3. CAP NUT ADJUSTED TO STOP KNOB WITH SPRING AT
(NOTE 4) FREE LENGTH 1/32 IN (0.79375 MM).
4. CYCLIC STICK LATERAL FRICTION MECHANISM IS SIMILAR
(SEE MAIN VIEW).
SPRING 5. IF NUT CAN BE TURNED WITH FINGER PRESSURE, NUT
CAP NUT MUST BE REPLACED.
DISC RETAINER (NOTE 3, 5)
TORQUE TUBE

FRICTION MECHANISM
(NOTE 4)
SCREW
PILOTS LATERAL
CONTROL ROD
SLOTTED BUSHING
(NOTE 1)
NYLON STRAP AND

MOUNTING PLATE
STA. 67 LATERAL DIM L

CYCLIC BELLCRANK CONTROL ROD INCH (CM) ANGLE A
PILOTS LATERAL 12.63 (32.0802 42
STA 70 LATERAL ) 6.65 (16.891) 90
MAXIMUM ALLOWABLE AXIAL

PLAY 0.040 IN. (1.016 MM)
LATERAL CONTROL ROD A (INBOARD END) RIVET
INBOARD END ATTACHMENT
G671022
Figure 604. Cyclic Stick and Friction Inspection
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Revision 28 671000
MAINTENANCE MANUAL
When replacing control rod (c). Check lower end of cyclic stick and
CAUTION ends, measure length accurate- play at attachment of cyclic intercon-
ly to ensure that replacement rod is exactly necting torque tube. Replace bearings
the same length as the original. Control rods and bushings as required.
are factory adjusted at installation to pro-
vide necessary clearances. (4). Check for axial play in cyclic trim
actuators.
(1). With the rotor stopped, check for free (a). Disconnect lower end of cyclic control
play at the cyclic stick grip. While rods from aft ends of trim actuators
moving cyclic stick through free play and check for free play. Remove free
range, have assistant check controls play by adjusting spring adjustment
mixer area for any free play motion. screw located in center recess at aft
end of actuator. If end play exceeds
0.0075 inch (0.1905 mm), replace
(a). Check pivot bolt areas where mixer actuator. Reconnect control rod.
bellcranks attach to control rod
bellcranks. If free play is noted, (b). Check for free play in attachments
remove pivot bolts and inspect for and linkages between trim actuators
wear and/or play between bolts, and cyclic pitch interconnecting
bushings, and bellcranks. Replace torque tube. Replace parts as re-
parts as required. quired; Install controls tunnel access
door.
(b). Check control rod assemblies by 14. Main Rotor Flight Control System
Pressing sidewards near the rod end 600Hour Inspection
bearing. Replace rod end as required.
(Ref. Figure 508)
(2). Check for free play in blade pitch links (1). With the rotor stopped, check for free
which connect rotating swashplate to play at the cyclic stick grip.
blade pitch housings. Replace rod ends
having free play in excess of 0.040 inch NOTE: If total free play at the top of the cyclic
(1.016 mm) side motion. grip is 3/8 inch (9.525 mm) or less in either
longitudinal or lateral direction inspection
is not required. If total free play at the top of
NOTE: Rod ends on pitch links should be the cyclic grip exceeds 3/8 inch (9.525 mm)
checked under a noload condition which is in either longitudinal or lateral direction,
best achieved by removing blades. perform the following:
(3). While moving cyclic stick through free (2). While moving cyclic stick through free
play range, check lower controls for free play range, have assistant check
play motion; Remove controls tunnel controls mixer area for any free play
access door. motion.
(a). Check each pivot bolt area where
(a). Check control rod assemblies by lateral mixer bellcranks attach to
pressing sidewards near the rod end collective bellcranks. If free play is
bearings. Looseness indicates axial noted at the lateral bellcranks,
play in rod end bearing. Replace rod remove pivot bolts and inspect for
end as required. wear and/or looseness between bolt,
bushings and bellcrank. Replace
parts as required.
(b). Check pivot bolt areas of lateral and
longitudinal bellcranks. If free play is (b). Check control rod assemblies by
noted, remove pivot bolts and inspect pressing sidewards near the rod end
for wear and/or play between bolts, bearings; motion here indicates axial
bushings, and bellcranks. Replace play in rod end bearing. Replace rod
parts as required. end as required.
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671000 Revision 39
MAINTENANCE MANUAL
(3). Check for free play in blade pitch links (a). Disconnect lower end of longitudinal
which connect rotating swashplate to cyclic control rod from aft end of trim
blade pitch housings. actuator and check for axial play.
Remove free play by adjusting spring
adapter screw located in center
NOTE: Both rod ends on each pitch link should recess at aft end of actuator assem-
be checked under a no load condition which bly.
is best achieved by removing blades. Re-
place rod ends having free play in excess of (b). Check for looseness in longitudinal
0.040 inch (1.016 mm) side motion. and lateral cyclic control rod ends,
located in tunnel. Replace rod ends
as required.
(4). Inspect lower controls for slack between (c). Check for free play in attachments
cyclic stick and attachment of the and linkages between trim actuators
longitudinal and lateral control rods to and cyclic pitch interconnecting
the mixer mechanisms, located just torque tube. Replace parts as re-
forward of the main rotor mast. quired. Reinstall access door.
When replacing adjustable rod
CAUTION ends, measure length accurate-
(5). Check lower end of cyclic stick for
looseness at the attachment point to ly to ensure that replacement rod is exactly
cyclic pitch interconnecting torque tube. same length as original. Mixer control rods
Replace bearings and/or bushings as are factory adjusted at original installation
required. to provide necessary clearances.
(8). Recheck for free play at the top of the
cyclic stick grip; as required, repeat
(6). Check interconnecting torque tube steps (1). thru (3). until total free play
bearings for free play; replace bearings at top of grip is 3/8 inch (9.525 mm) or
if excessive free play is noted. less in either longitudinal or lateral
direction.
(7). Check for axial play in cyclic trim (9). If replacement of parts is required
actuators (remove access door at lower perform rigging of main rotor controls
end of pilots bulkhead center tunnel in (Ref. Collective Controls Rigging and
the cargo compartment). Cyclic Controls Rigging).
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MAINTENANCE MANUAL

REPAIRS
1. TunnelRouted Control Rod Repair A. Control Tube End Sleeve Installation

Item Nomenclature
(1). Perform straightness check on control CM219 Methylethylketone
rod that appears bent or bowed. Total CM229 Paint remover
length of any tunnelrouted rod
(excluding rod ends) must be straight CM230 Paint remover
within 0.050 inch (1.270 mm), with CM231 Plastic bead, spherical 20 30 mesh
straightness variation limited to CM318 Primer
maximum of 0.010 inch (0.254 mm) in CM409 Adhesive, epoxy
each foot of length.
(1). Remove all four control rods (Ref.

Dyecheck for cracking TunnelRouted Control Rod Replace-
WARNING must always be performed
ment).
after coldstraightening. Replace
cracked rod, or cracked or bent rod (2). Using paint remover (CM229, CM230
end. or CM231) remove paint approximately
six inches back from end of each tube,
tape and coverrap remaining area of
(2). Coldstraighten bent rod that is not tube.
within tolerance (step (1). above)
provided there are no nicks or sharp NOTE: Control tubes that are cracked must be
dents in bent length. Do not use rod removed from service.
ends to support rod during straighten-
ing. (3). Dye penetrant inspect external surface
of stripped area for cracks.
Use care when drilling to re-
CAUTION move or install riveted rod end;
(a). Cracked are indicated by heavy bleed
out. It may be necessary to wipe off
rod end is steel and rod is aluminum. and reapply the developer to distin-
guish between surface defects caused
during swaging operation.
(3). Replace control rod end if bearing axial
play is more than 0.040 inch (1.016 (b). Light penetrant indications are not
mm). Set initial control rod length (Ref. cause for rejection.
Figure 601).
(4). If no cracks are found; inspected control
tube can be reworked for sleeve instal-
2. TunnelRouted Control Tube Inspection lation. All four control tubes are to be
and Sleeve Installation reworked as follows:
(a). Measure and record length of control

(Ref. Figure 801) The following procedures are tubes for reinstalling rod ends and to
for inspection and installation of reinforcing prevent rerigging after tube rein-
sleeves to the tunnelrouted control tubes. stallation.
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671000 Revision 21
MAINTENANCE MANUAL
0.0970.102 IN.
(2.46382.5908 MM) DIA 0.340 IN. *
(8.635 CM)
SLEEVE
CONTROL TUBE
0.750 IN. *
A DIA (19.05 MM) DIA.
7 0.5
0.0000.080 IN.
(0.0002.032 MM)
0.720 IN. *
(18.288 MM)
0.910 IN. *
(23.114 MM)
G671035A
Dimensional Table
Sleeve No. Dim A Tube O.D.

Rod No.
369D27013 inch (mm) inch (mm)
369A7007 1 0.5400.545 (13.71613.843) 0.5010.530 (12.725413.462)

369A7009 2 0.5100.515 (12.95413.081) 0.4700.500 (11.93812.70)
3 0.5900.595 (14.98615.113) 0.5510.580 (13.995414.732)

369A7011
4 0.5600.565 (14.22414.351) 0.5200.550 (13.20813.970)
369A7012 5 0.5700.575 (14.47814.605) 0.5300.560 (13.46214.224)
NOTES:
(1) Material; 2024T351 or T4 (QQA 225/6) bar or round stock
(2) Break sharp edges 0.0050.015 inch (0.1270.381 mm).
(3) Surface finish 125 RMS.
(4) Chemical film per MILC5541.
(5) Tolerance * 0.010 inch (0.254 mm).
Figure 801. Sleeve Fabrication and Installation
Page 802
Revision 21 671000
MAINTENANCE MANUAL
Drilled out rivets may damage Do not use heat gun. Use of heat
CAUTION threads upon removal. Visually CAUTION lamp is acceptable.
inspect control tube threads for damage
from rivet and rod end removal. Replace (i). Allow to cure for 24 hours at mini-
damaged control tubes. Drilled rod ends are mum ambient temperature of 68F
matched drilled to each control tube and (20C) (alternate cure 4 hours at
must be reinstalled into control tube end 115140F (4760C)).
from which removed.
(j). Repeat procedure for ends of each
control tube.
(b). Remove rod ends, MS20470AD3
rivets must be removed from fixed
end. (k). Using primer (CM318), touchup
repaired area(s) of control tube.
(c). Measure outside diameter of control (l). Install rod ends into ends in which it
tube end and select proper sleeve. was removed. On fixed rod end, align
witness/rivet hole in sleeve and tube
with rivet hole in rod end. Drill (#40)
(d). Temporarily install sleeve onto thru opposite end of sleeve. Rivet
control tubes. Align sleeve and fixed end with MS20470AD315
control tube witness hole. If sleeve rivet.
protrudes past end of control tube,
trim end of sleeve flush to 0.000 inch (m). Adjust each control tube to its
(0.000 mm) or back 0.080 inch (2.032 previously measured length and
mm) from end of tube. paint the control tube ends with
primer. Paint adjustable ends of
control tube flat black.
NOTE: Bond integrity is dependent on clean
surfaces. (n). Reidentifiy, with permanent ink, the
control tubes that have been re-
worked (Ref. Table 801).
(e). Thoroughly clean end of control tube
and interior surface of sleeve with
lint free cloth and MEK (CM219) or Table 801. Control Tube ReIdentification
equivalent.
Old Part Number New Reworked Part Number
369A7007 369A70075
(f). Mix epoxy adhesive (CM409) per 369A7009 369A70095
369A7011 369A70115
369A7012 369A70125
(g). Remove excessive adhesive with lint
free cloth moistened with MEK or
equivalent. Do not saturate the (o). Rework control tube boot (Ref.
cleaning cloth. Remove adhesive from Figure 802).
witness holes.
If control rod is not accurately
CAUTION measured, flight controls will
(h). Plug end of control tube to prevent require rerigging.
adhesive from entering threads. Bond
sleeve to control tube. Apply adhesive (p). Reinstall control tubes. Reinstall
to both surfaces and install sleeve. trimmed boot with vertical seam
Align witness/rivet hole in sleeve and facing aft. Check flight controls for
tube. interference or binding.
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671000 Revision 21
MAINTENANCE MANUAL
B. Control Tube Straight Area Sleeve (2). Tape around area to be repaired.
Installation
(3). Using paint remover (CM229, CM230
This repair is permissible on the straight area or CM231), strip paint 1.0 inch (2.54
of the tube only and increases the outside cm) beyond area of repair.
diameter.
(4). Polish out burrs and sharp edges.
Consumable Materials Ensure defects do not exceed allowable
(Ref. Section 910000) limits (Ref. Table 801). Dye penetrant
Item Nomenclature inspect area per MILI25135; no
CM219 Methylethylketone cracks allowed.
CM229 Paint remover
NOTE: Bond integrity is dependent on clean
CM230 Paint remover surfaces.
CM231 Plastic bead, spherical 20 30 mesh
CM318 Primer (a). Thoroughly clean repair area of
CM409 Adhesive, epoxy control tube and interior surface of
sleeve with lint free cloth and MEK
(CM219) or equivalent.
NOTE:
D Ensure adequate clearance exists prior to (b). Mix epoxy adhesive (CM409) per
performing the repair. Determine and re- manufacturers instructions.
pair condition that caused damage.
D Maximum length of repair sleeve is 6 in- (c). Apply adhesive to both surfaces and
ches (15.24 cm). Two sleeve repairs per- install sleeve.
mitted per control tube.
(d). Remove excessive adhesive with lint
(1). Remove damaged control rod(s) (Ref. free cloth moistened with MEK or
TunnelRouted Control Rod Replace- equivalent. Do not saturate the
ment). cleaning cloth.
Table 802. Control Tube Straight Area Repair Limits
Nicks and Gouges (2) Dents and Depressions (2) Repair Sleeve (3)
Tube Max. Depth Max. Depth Max. Depth Max. Depth Wall
369A W/O Repair (4) With Repair (1) W/O Repair (4) With Repair (1) O.D.
Thickness
inch (cm)
Inch (mm) inch (mm) inch (mm) inch (mm) inch (mm)
7007 0.006 (0.152) 0.015 (0.381) 0.010 (0.254) 0.025 (0.635) 1.375 (3.4925) 0.049 (1.2446)
7009 0.008 (0.203) 0.020 (0.508) 0.010 (0.254) 0.025 (0.635) 1.50 (3.81) 0.049 (1.2446)
7011
0.010 (0.254) 0.025 (0.635) 0.010 (0.254) 0.025 (0.635) 1.625 4.1275) 0.049 (1.2446)
7012
NOTES:
(1) Sleeve repair not permitted in tapered area. Two sleeve repairs per control tube. Maximum defect area
0.375 in2 (2.41935 cm2) per sleeve.
(2) Must be free of burrs and sharp areas.
(3) Aluminum tube 6061T6 WWT700/6 or 2024T3 WWT700/3. Alternate: field fabricate from
2024T351 or 2024T4 (QQA225/6 or QQA200/3). Inside diameter to be 0.0100.025 inch
(0.2540.635 mm) larger than outside diameter of tube to be repaired. Outside diameter as listed in table,
0.010 inch (0.254 mm) and concentric to inside diameter 0.005 inch (0.127 mm). Maximum length of
repair sleeve 6 inches (15.24 cm). Break sharp edges 0.0050.015 inch (0.1270.381 mm).
(4) Maximum defect area without repair 0.10 in2 (0.64516 cm2) total. For threaded area, last 2 inches (5.08
cm) of both ends, maximum depth of defect 0.020 inch (0.508 mm).
Page 804
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MAINTENANCE MANUAL
Do not use heat gun. Use of heat 5. Controls Support Bracket and Bellcrank
CAUTION lamp is acceptable. Reassembly
(e). Allow to cure for 24 hours at mini- (Ref. Figure 403)
mum ambient temperature of 68F
(20C) (alternate cure 4 hours at (1). Install longitudinal idler bellcrank.
115140F (4760C)). Check that slotted bushing is in place
in support bracket lug, and reinstall
(f). Using primer (CM318), touchup shim washers between bellcrank and
repaired area(s) of control tube. bracket for no sideload of oneway lock.
3. Controls Support Bracket and Bellcrank NOTE: When performing following steps, en-
Disassembly sure that slotted bushing is in support
bracket lug.
(Ref. Figure 403)
NOTE: In following steps, do not remove (2). Install lateral idler bellcrank.
slotted bushings unless replacement is nec-
essary. (3). Install tail rotor bellcrank.
(1). Remove lateral idler bellcrank. 6. Pilots Collective Pitch Stick Disassembly
(L/H Command)
(2). Remove tail rotor bellcrank.
(Ref. Figure 602)
(3). Remove longitudinal idler bellcrank.
(1). Cut two nylon straps, and remove stick
NOTE: Shim washers between longitudinal friction mechanism guard.
idler bellcrank and support brackets align
oneway lock for no sideload. Keep shim
(2). Remove setscrews that secure switch
washers with bracket for use during reas-
housing.
sembly.
NOTE: Removal of additional setscrew is also
4. Controls Support Bracket and Bellcrank required on helicopters equipped with cargo
Repair release mechanism.
(Ref. Figure 403)
(3). Cut nylon strap or twine that secures
electrical wiring to stick tube. Push
Consumable Materials wire slack into stick, carefully pull
(Ref. Section 910000) housing and wiring from end of stick
Item Nomenclature tube and disconnect wiring from
CM321 Surface primer locking compound switches.
(4). Remove setscrew and wire guide from
forward end of stick. Tie string on each
(1). Replace unserviceable bearings. Install wire bundle to aid reassembly and
new bearing with surface primer remove wiring.
(CM321) and grade A locking compound
(CM431). (5). Remove spring and idle stop release
ring.
NOTE: When idler bellcrank bearings are re-
placed, make sure that idler bellcrank (6). Remove grip attach bolts. Slide throttle
spacers are reinstalled between bearings. grip friction washer and discs, and
friction nut from stick tube.
(2). Replace bellcranks or controls support
bracket that has distortion, cracks or (7). Remove friction mechanism and guide
elongated holes. from stick fitting.
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671000 Revision 21
MAINTENANCE MANUAL
SEWN SEAMS SEWN SEAMS
2 PLACES
0.400.50 IN.
(10.1612.70 MM)
(NOTE 1)
DOUBLE BOOT SINGLE BOOT

NOTES:
1. TRIM BOOTS BELOW HORIZONTAL SEAM.
CAUTION: DO NOT USE SOLVENTS OR PETROLEUM BASED CLEANING
FLUIDS ON VINYL BOOTS.
2. CLEAN INSIDE AND OUTSIDE OF VERTICAL SEAM AND TOP OF
BOOT WITH CLEAN CLOTH DAMPENED WITH ISOPROPYL ALCOHOL.
3. COAT BOTH SIDES OF VERTICAL SEAM WITH CONTACT CEMENT.
4. APPLY THIN COAT OF CONTACT CEMENT ALONG TRIMMED EDGE
AND 0.1250.250 INCH (3.1756.350 MM) DOWN INSIDE AND OUTSIDE
SURFACES OF BOOTS TO PREVENT FRAYING. G671036A
Figure 802. Control Tube Boot Rework

(8). Remove idler gear from stick fitting. (1). Replace bearings if corroded, excessive-
ly worn, or if outer or inner races of
NOTE: In following steps, do not remove bear- bearings rotate on mating surfaces and
ings or pinion unless replacement is neces- locking compound is inadequate to
sary. prevent rotation.
(2). Replace loose rivets in gas producer
(9). Remove cap from stick housing.
control tube.
(10). Remove gear shaft assembly. Keep (3). Replace friction drive gear or idler gear
backlash shims with gear shaft. with cracked, chipped or broken teeth.
(4). Replace friction drive gear if it does not
(11). Remove cover from back of stick
rotate freely on stick tube, or if rotating
housing.
stop is damaged. To remove gear, drill
out rivets that attach throttle friction
(12). Remove gas producer control tube
nut fitting to stick.
through access hole at back of stick
housing. Remove mounting distance NOTE: Before replacing drive gear for binding,
shim only if necessary to adjust pinion clean and relubricate bore with grease
gear mounting distance. (CM116). Reinstall gear on stick tube and
recheck for free rotation. If gear still binds it
7. Pilots Collective Pitch Stick Repair (L/H must be replaced.
Command) (5). Replace phenolic friction washers
against guide if worn to less than 1/32
(Ref. Figure 602) inch thickness.
(6). Replace friction gear assembly if driven
Consumable Materials gear has cracked, chipped or broken
(Ref. Section 910000) teeth or if cam pin is bent.
Item Nomenclature
(7). Replace damaged idle stop release ring.
CM116 Grease, aircraft and instrument Ring must slide freely on tube and in
throttle grip.
Page 806
Revision 21 671000
MAINTENANCE MANUAL
8. Pilots Collective Pitch Stick Reassembly removed during disassembly. (One edge
(L/H Command) of shim must be cut for installation.)
(Ref. Figure 602) NOTE: Steps (6). thru (8). below are used to de-
termine gas producer control tube pinion
mounting distance.
(Ref. Section 910000) (6). Install approximate required thickness
Item Nomenclature of split shims between pinion bearing
CM116 Grease, aircraft and instrument and housing to establish gas producer
control tube pinion mounting distance.
CM807 Twine, nylon (7). Use throttle friction nut to pull gas
CM815 Solder producer torque tube forward until not
less than 10 pounds (44.48 N) of force is
applied to compress shims.
(1). Check gearshaft bearings in housing
(8). Add or subtract shims to provide
cap a housing for security of outer
0.6990.709 inch (17.754618.0086
races. Use grade A locking compound
mm) dimension (Ref. Figure 504).
(CM431) to install replacement bear-
Repeat step (7). during each measure-
ings. Use care to prevent compound
ment.
from entering bearings, and make sure
that each bearing is seated against its (9). After mounting distance shimming is
bore shoulder. correct, remove gas producer control
tube and apply grade A locking com-
(2). Using grease (CM116), lubricate stick pound (CM431) to outside diameter
tube interior where gas producer pinion bearing outer race and stick
control tube fitting makes contact. housing bore. Reinstall control tube,
and check that compound does not
(3). Attach strings routed through stick
enter bearing and that bearing outer
tube during disassembly, and thread
race and shims are firmly seated
electrical wire bundles from plug
against housing bore.
through exit hole, throttle friction nut,
friction washers and discs, throttle grip, (10). Install throttle friction nut, friction
idle stop release ring and spring. Pull discs and washers.
wiring out through front end of stick
tube. (11). Using grease (CM116), lubricate
interior of throttle grip and install grip
(4). Install wire guide so that it divides on stick tube. Align grip and gas
switch wiring: three wires in one cutout producer control tube fitting and install
and four in the other. Align guide with grip attach bolts. When tightened, bolts
matching hole in stick tube and install must be flush or not more than 0.010
setscrew. When tightened, setscrew inch (0.254 mm) below outer face of
must be flush or not recessed more than grip.
0.010 inch (0.254 mm) below outer tube
surface. (12). Establish gas producer control tube
pinion and shaft assembly bevel gear
NOTE: Ensure gas producer control tube is in- backlash by temporarily installing
stalled into stick housing with elongated driven gear, shaft, and two bearings,
area of fitting facing down. plus approximate required thickness of
backlash shims in housing. Temporarily
(5). Install gas producer control tube install housing cap. Add or subtract
through access hole in back of stick shims to provide maximum backlash of
housing, and through stick tube until 0.003 inch (0.076 mm) without bind in
control tube fitting engages wire guide gears. Make certain that bearings are
bore. Reinstall mounting distance completely seated in bores while
shims forward side of pinion bearing if establishing this backlash adjustment.
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671000 Revision 21
MAINTENANCE MANUAL
(13). After backlash shimming is correct, (22). Adjust collective friction mechanism.
remove housing cap and gear shaft.
9. Pilots Collective Pitch Stick Disassembly
(14). Lubricate teeth of pinion gear and shaft (R/H Command)
assembly bevel gear with grease
(CM116). (Ref. Figure 603)
(15). Apply grade A locking compound (1). Disassemble collective stick to extent of
(CM431) to secure gearshaft to bear- removing friction mechanism idler gear
ings. Do not allow compound to enter from stick fitting, except also remove
bearings. With throttle grip at midtra- screw and nut to disconnect electrical
vel, install driven gear. Note that at terminals from stick housing.
throttlegrip midtravel, cut out (2). Detach link and idler.
portion of the driven gear is to be
opposite pinion gear. (Centerline of (3). Remove idler from socket housing. Do
center tooth of driven gear is two not remove idler bearing unless
degrees and fifty minutes from center of replacement is necessary.
driven gear cutout.)
(4). Remove four bolts and washers that
NOTE: With throttle grip at midtravel, two attach housing cap to socket housing.
grip attach bolts are positioned approxi- Rotate shaft assembly until gear tooth
mately straight down. cutout clears pinion (bellcrank ears at
approximately 195 degrees);, then
(16). Install housing cap on shaft assembly separate bellcrank, housing cap and
and seat with hand pressure while shaft assembly from housing.
slowly rotating grip back and forth.
Secure cap to side of housing and cover (5). Remove bellcrank from shaft assembly
to back of housing. to separate housing cap from shaft. Do
not press bearings from cap or housing
(17). Using solder (CM815), connect wiring unless replacement is necessary. Keep
to stick switches. Pull electrical wiring backlash shims with shaft assembly.
slack out through exit holes in stick
tube, position release ring and. spring (6). Remove link from bellcrank.
and install switch housing with set-
(7). Remove gas producer control tube
screws. Using nylon strap, or twine
through access hole at back of pilots
(CM807), secure electrical wiring to
collective stick housing.
stick tube approximately one inch aft of
exit holes. (8). Remove mounting distance shim only if
necessary to adjust pinion gear mount-
(18). Install friction cam and driven gear ing distance.
assembly on stick fitting. Temporarily
mesh idler gear and driven gear, and (9). Remove pinion and bearing from
rotate friction drive gear counterclock- control tube only if replacement is
wise to maximum stop. necessary.
(19). Hold drive gear at stop and remesh 10. Pilots Collective Pitch Stick Reassembly
idler gear and driven gear so that gear (R/H Command)
assembly pin is at high point of cam.
(Ref. Figure 603)
(20). Use shim washers sufficient to limit
gear end play to maximum of 0.010 inch
(0.254 mm), and secure idler gear with
cotter pin.
Item Nomenclature
(21). Assemble remainder of friction mecha- CM431 Sealing, locking and retaining compound
nism.
Page 808
Revision 21 671000
MAINTENANCE MANUAL
(1). Check gearshaft bearings in housing (7). Remove cap from stick housing. Do not
cap and housing for security of outer remove bearing from cap unless
races. Use grade A locking compound replacement is necessary.
(CM431) to install replacement bear-
ings. Use care to prevent compound (8). Remove gearshaft assembly. Keep
from entering bearings, and make sure backlash shims with gearshaft and do
that each bearing is seated against its not remove bearing from stick housing
bore shoulder. unless replacement is necessary.
(2). Completely reassemble pilots collective (9). Remove cover from back of stick
stick to the extent of assembling housing.
friction mechanism. (10). Remove gas producer control tube
through access hole in back of stick
(3). Connect two electrical terminals to housing. Remove mounting distance
stick housing. shim only if necessary to adjust pinion
(4). Shim and adjust pinion mounting gear mounting distance. Remove pinion
distance and backlash. and bearing from control tube only if
replacement is necessary.
(5). After backlash shimming is correct,
install bellcrank on shaft assembly and 12. Copilots Collective Pitch Stick Repair
link to bellcrank; then install, seat and (1). Replace bearings if locking compound
secure housing cap on stick housing. Do does not prevent outer or inner races
not adjust collective friction mechanism from rotating on mating surfaces, if
at this point of assembly. corroded, or if excessively worn.
(6). Install idler to the stick housing, and (2). Replace loose rivets in gas producer
link to the idler. control tube, or damaged pinion gear.
(7). Adjust the collective friction mechanism 13. Copilots Collective Pitch Stick
(Ref. Collective Stick Friction Mecha- Reassembly
nism Adjustment).
11. Copilots Collective Pitch Stick Consumable Materials

Disassembly (L/H and R/H Command) (Ref. Section 910000)
Item Nomenclature
(1). Cut nylon strap or twine securing CM116 Grease, aircraft and instrument
wiring to stick tube.
(2). Remove setscrews that secure the CM807 Twine, nylon
switch housing. CM815 Solder
(3). Push wire slack into stick and carefully

pull switch housing from end of stick (1). Check gearshaft bearings in housing
tube; disconnect wiring from N2 switch cap and housing for security of outer
(Ref Chap. 96). races. Use grade A locking compound
(CM431) to install replacement bearing.
(4). Remove grip attach bolts and grip. Use care to prevent compound from
entering bearings, and make sure each
(5). Remove adjusting nut pin and throttle
bearing is seated against its bore
end play adjusting nut only if stick tube
shoulder.
replacement is necessary, or if end play
must be adjusted. (2). Using grease (CM116), lubricate stick
tube interior where gas producer
(6). Remove setscrew and wire guide. Tie a control tube fitting makes contact.
fish string on end of wire bundle to
aid reassembly, and then remove the (3). Attach fish string (routed through
wiring. stick during disassembly) and thread
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671000 Revision 21
MAINTENANCE MANUAL
electrical wire bundle from electrical (12). Apply grade A locking compound
plug through exit hole in stick tube and (CM431) to gearshaft and ID of bear-
out front end of tube. ings. With throttle grip at midtravel,
install shaft assembly gear.
(4). Install wire guide in stick tube so it
positions wire bundle in right cutout of (13). Install housing cap on gearshaft and
guide. Align guide with matching hole seat with hand pressure while slowly
in stick tube, and install setscrew. rotating grip back and forth. Secure cap
When tightened, setscrew must be at on side of housing and cover on back of
least flush and not recessed more than housing.
0.010 inch (0.254 mm) below outer (14). Check throttle grip for zero end play on
surface of tube. stick tube and that not more than 1
(5). Install gas producer control tube pound torque is required to rotate the
through access hole in back of stick grip. If these conditions exist, proceed
housing, and through stick tube until with step (18). below. If there is end
control tube fitting engages wire guide play, or too much torque is required to
bore. Reinstall mounting distance rotate the grip, perform steps (15)., (16).
shims at forward side of pinion bearing and (17).
if removed during disassembly. (One (15). Remove grip attach bolts and grip.
edge of shims must lie cut for installa-
tion.) (16). Insert 3/64 inch (1.190625 mm) diame-
ter drift punch into access hole on
(6). Establish gas producer control tube forward face of adjusting nut and drive
pinion mounting distance (Ref. Gas grooved taper pin from adjusting nut
Producer Linkage Adjustment). and threaded fitting of stick tube.
(7). After mounting distance shimming is (17). Reinstall grip with grip attach bolts
correct, remove gas producer control and establish zero end play and correct
tube and apply grade A locking com- rotational friction, 1 pound (4.448 N)
pound (CM431) to OD of pinion bearing maximum, between nut and grip. The
outer race, and stick housing bore. matchdrill 3/64 inch (1.190625 mm)
Reinstall control tube and check that maximum diameter stick tube fitting
compound does not enter bearing and threads to existing pin groove in nut,
that bearing outer race and shims are and install pin.
firmly seated against housing bore. (18). Using solder (CM815), connect wiring
to N2 switch. Pull electrical wiring
(8). Using grease (CM116), lubricate ID of
slack out through exit hole in stick tube
throttle grip and install grip on stick
and install switch housing with set-
tube. Align grip and gas producer
screws. Using nylon strap or twine
control tube fitting and install grip
(CM807), secure electrical wiring to
attach bolts. When tightened, bolts
stick tube, approximately one inch (2.54
must be at least flush and not recessed
cm) aft of exit hole.
more than 0.010 inch (0.254 mm) below
outer surface of grip. 14. Collective Control Interconnecting Torque
Tube Repair
(9). Establish gas producer control tube
pinion and gearshaft bevel gear (Ref. Figure 407)
backlash.
(1). Replace loose or binding torque tube
(10). After backlash shimming is correct, sup port bearings. Drill out rivets
remove housing cap and gearshaft. securing retainer and doubler to seat
structure to replace left support
(11). Lubricate teeth of pinion gear and bearing. Drill out three rivets securing
gearshaft bevel gear with grease right end fitting to torque tube to
(CM116). replace right support bearing. Install
Page 810
Revision 21 671000
MAINTENANCE MANUAL
new bearings and rivets at existing 16. Collective Bungee Reassembly

holes.
(Ref. Figure 407)
(2). Replace torque tube if it is cracked or
has elongated holes. Consumable Materials
Item Nomenclature
NOTE: Torque tube droop control bracket may CM116 Grease, aircraft and instrument
be either an aluminum or magnesium cast-
ing. (For corrosion control and identification
of magnesium and aluminum alloy parts, Special Tools
Ref. Sec. 204000.) (Ref. Section 910000)
Item Nomenclature
(3). Replace bent or stripped bungee
adjusting bolt. Torque nut to 30 40 ST509 Not used at this time
inchpounds (3.39 4.52 Nm). ST510 Bungee spring compression tool rod and
channel
(4). Replace scratched, nicked or otherwise
damaged reinforcement strap. (1). Lubricate cups of spring retainers and
threads and bore of female bearing
assembly with grease (CM116).
15. Collective Bungee Disassembly
(2). Assemble retainer, spring and female
bearing assembly. Install compression
(Ref. Figure 407) tool rod and channel (ST510). Insert a
1/4 inch (6.35 mm) bolt through channel
and female bearing rod end.
Special Tools
(Ref. Section 910000) (3). Position assembly in bench vise.
Item Nomenclature Compress bungee spring until bungee
ST510 Bungee spring compression tool rod and
installation tool (ST508 or ST509) fits
channel
over retainers. Secure tool halves in
place with clamp.
(4). Open vise slowly and remove bungee
(1). Remove male bearing from bungee compression tool rod and channel.
clamped in compression by installation (5). Install male bearing in compressed
tool. bungee.
(2). Install bungee compression tool rod and 17. Inboard Collective Stick Socket Assembly
channel (ST510) on compressed bungee. Disassembly
Insert 1/4 inch (6.35 mm) bolt through (Ref. Figure 408)
channel and female bearing rod end.
(1). Disconnect link from idler.
(3). Place compression tool and bungee in (2). Remove idler from socket housing. Do
vise so that vise jaws make contact with not remove idler bearing unless
tool rod and channel. Compress vise replacement is necessary.
and remove bungee clamp.
(3). Remove four bolts and washers that
attach housing cap to socket housing.
(4). Slowly open vise and remove bungee Rotate shaft assembly until gear tooth
components. cutout clears pinion (bellcrank ears at
approximately 195 degrees); then
NOTE: Do not disassemble female bearing as- separate bellcrank, housing cap and
sembly; if defective, replace as a unit. shaft assembly from housing.
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671000 Revision 21
MAINTENANCE MANUAL
(4). Remove bellcrank from shaft assembly 19. Inboard Collective Stick Socket Assembly
to separate housing cap from shaft. Do Reassembly
not press bearings from cap or housing (Ref. Figure 408)
unless replacement is necessary. Keep
backlash shims with shaft assembly.
(5). Remove link from bellcrank. Item Nomenclature
(6). Remove snap ring that retains N1
pinion gear aft bearing in housing.
Press pinion gear and aft bearing, as an (1). Check gearshaft bearings in housing
assembly, out through access hole at the cap and housing for security of outer
back of housing. Disassemble pinion races. Use grade A locking compound
bearings from pinion and housing only (CM431) to install replacement bear-
if replacement is necessary. ings. Use care to prevent compound
from entering bearings, and make sure
that each bearing is seated against bore
18. Inboard Collective Stick Socket Assembly shoulder.
Repair (2). Apply grade A locking compound
(CM431) to pinion gear aft bearing
outer circumference and matching bore
(Ref. Figure 408) in socket housing. Install assembled N1
pinion gear and aft bearing; seat
bearing firmly against bore shoulder.
(3). Install snap ring that retains aftbear-
ing in housing bore. Apply locking
Item Nomenclature
compound to bond pinion shaft to
CM116 Grease, aircraft and instrument forward bearing and to bond forward
bearing to housing bore. Press bearing
firmly against housing shoulder.
(Housing is machined to provide a light
(1). Replace bearings if corroded, excessive- pressfit.)
ly worn, or if outer or inner races of
bearings rotate on mating surfaces and (4). Establish N1 pinion and shaft assembly
locking compound does not prevent bevel gear backlash by rotating N1
rotation. Install new bearings with pinion gear assembly so that wide
grade A locking compound (CM116). toothspace on spline is at about one
Check that replacement bearing is oclock when viewed from socket
properly seated in mounting bore. (looking aft). Install backlash shims to
obtain maximum backlash of 0.003 inch
(0.076 mm) with bearings firmly seated
(2). Replace any cracked part. in bores.
(5). After backlash shimming is correct,
(3). Replace entire link if bearings are remove housing cap and gearshaft.
defective; link bearings are not replace- (6). Install bellcrank on shaft assembly, and
able. link to bellcrank.
NOTE: Bellcrank attachment bolt must be in-
(4). Replace pinion gear or shaft assembly stalled with head slightly down and for-
bevel gear when correct backlash ward.
cannot be maintained because of tooth (7). Lubricate teeth of pinion gear and shaft
irregularities caused by wear or assembly bevel gear with grease
deformation. (CM116).
Page 812
Revision 21 671000
MAINTENANCE MANUAL
(8). Apply grade A locking compound 22. Lateral Control Rods and Sta. 67
(CM431) to bond bevel gearshaft and Bellcrank Repair
bearings. With centerline of wide
toothspace of N1 pinion gear spline up (Ref. Figure 411)
(on top), install shaft assembly gear at
midtravel position. Consumable Materials
NOTE: N1 pinion shaft spline wide toothspace Item Nomenclature
should be positioned up at approximately
one oclock position, as viewed looking aft
into open end of socket.
(1). Replace Sta. 67 lateral bellcrank if it
(9). Install four bolts, eight washers, four has elongated holes or is cracked.
spacers and nuts to secure cap to Replace pivot bearing if it binds or is
housing. excessively worn; install with grade A
locking compound (CM431). Check free
(10). Install idler to housing, and link to play of bellcrank with newly installed
idler. pivot bearing by applying light up and
down pressure at forward end of
NOTE: When installed, idler to gas producer bellcrank with bearing secured. For
control rod bolt holes should be in line with bearing to be acceptable, bellcrank total
centerline of stick assembly housing cap play measured at centerline of bolt that
when gearshaft and pinion gears are posi- attaches pilots lateral control rod end
tioned as outlined in step (8). above. must not exceed 0.024 inch (0.6096
mm).
20. Cyclic Control Stick Repair
NOTE: Sta. 67 lateral bellcrank may be either
(Ref. Figure 411) Disassemble cyclic control an aluminum or magnesium machined forg-
stick only as necessary to replace damaged or ing. (For corrosion control and identification
faulty parts. Pilots stick tube should not be of magnesium and aluminum alloys, Ref.
removed from stick socket; the assembly Sec. 204000.)
should only be replaced as a unit.
(2). Perform straightness check on control
rod(s) that appear bent or bowed. Total
21. Cyclic Friction Mechanism Repair length of rod (excluding rod ends) must
be straight within 0.010 inch (0.254
(Ref. Figure 603) mm). Coldstraightening of rod is
permissible if no nicks or sharp dents
(1). Remove cap nut from friction stud and exist in bend length, and rod ends are
disassemble friction mechanism from not used to support rod during straight-
stick socket or torque tube. ening process. Dyecheck for cracking
is to be performed after coldstraigh-
(2). Replace bent or stripped friction stud.
tening. Replace cracked rod, or cracked
Drill out rivet and press stud from
or bent rod end.
socket; install new stud and rivet in
place. Press replacement spring pin Use care when drilling to re-
into friction stud until one end of pin is CAUTION move or install riveted rod end;
flush with surface of stud. rod end is steel and rod is aluminum. Do not
tighten adjustable rod end jam nut on pilots
(3). Assemble friction mechanism to stick lateral control rod until rod is installed and
socket or torque tube. cyclic stick longitudinal travel is checked.
(4). Adjust friction knob cap nut to stop (3). Replace control rod end if bearing axial
knob when spring extends to free play is more than 0.040 inch (1.016
length, no compression 1/32 inch mm). Set initial control rod length and
(0.79375 mm). bearing angularity.
Page 813
671000 Revision 21
MAINTENANCE MANUAL
23. Cyclic Pitch Interconnecting Torque Tube (CM801) to remove rough edges. Finish
Repair by polishing with crocus cloth (CM803);
maintain smooth transition into
(Ref. Figure 412) surrounding area. After repair treat
area with chemical film (CM206).
Consumable Materials (2). When replacing input (forward) shaft
(Ref. Section 910000) rod end bearing, with piston at mid
Item Nomenclature stroke ensure bearing centertocenter
CM116 Grease, aircraft and instrument distance is 8.58 0.030 inches (217.932
CM431 Sealing, locking and retaining compound 0.762 mm). Adjust as required. After
correct length is set, tighten and safety
lock nut with lockwire.
NOTE: Cyclic torque tube may be either a ma-
chined magnesium or aluminum casting. NOTE: Support links may be either forged alu-
(For corrosion control and identification of minum or magnesium castings. (For corro-
magnesium and aluminum alloys, Ref. Sec. sion control and identification of magne-
204000.) sium and aluminum parts, Ref. Sec.
204000.)
(1). Replace torque tube if it is cracked, has
elongated holes or deformed bearing 25. Cyclic Trim Actuator Spring Assembly
supports. Replacement
(2). Replace main support bearings or cyclic (Ref. Figure 508)
stick pivot bearings if they bind or are
excessively worn. Drill out four rivets Consumable Materials
and remove bearing retainer to replace (Ref. Section 910000)
right support bearing. Install cyclic Item Nomenclature
stick pivot bearing and right support CM116 Grease, aircraft and instrument
bearing with grade A locking compound
(CM431). CM234 Solvent, drycleaning
NOTE: Left support bearing is a slipfit in (1). Insert screwdriver into open end of
torque tube lug; coat outer circumference of
spring guide and remove screw that
bearing with grease (CM116) prior to inser-
connects two spring adapters.
tion in lug.
NOTE: Identify screw for lateral or longitudi-
(3). Replace bent or stripped friction stud. nal trim; screws are not interchangeable.
Drill out rivet; install and rivet new Lateral actuator screw is 27/8 inches
stud in place. Insert spring pin with one (73.025 mm) long; longitudinal screw is
end flush with stud. 25/8 inches (66.675 mm) long.
24. OneWay Lock Repair (2). Slide spring assembly out of trim tube.
For overhaul information, Ref. COM. (3). Clean inside of trim tube with solvent
(CM234).
Consumable Materials (4). Coat outside of replacement spring
(Ref. Section 910000) assembly tube lightly with grease
Item Nomenclature (CM116).
(5). Slide replacement spring assembly into
CM801 Abrasive paper, silicon carbide trim tube.
CM803 Crocus cloth
(6). Install spring adapter screw in open
end of spring assembly and tighten
(1). Remove dents, nicks and scratches by screw until 0.0100.050 inch
using grade 400 abrasive paper (0.2541.27 mm) play is felt while
Page 814
Revision 31 671000
MAINTENANCE MANUAL
pushing or pulling on spring assembly. 27. Cyclic Trim Actuator (Motor/Gear Drive
While tightening screw, check that Mechanism) Replacement
friction exists from selflocking
threaded insert. (Ref. Figure 508)
(1). Remove actuator spring assembly.
(7). Wipe off all excess grease.
(2). Remove trim tube.
(8). Perform bench test to check actuator
(3). Support actuator tube and press out
operation.
spring pin.
26. Cyclic Trim Actuator Housing or Trim (4). Unscrew adapter from actuator and
Tube Replacement remove actuator from housing.
(5). Screw adapter into replacement
(Ref. Figure 508)
actuator shaft until it bottoms. If spring
pin hole drilled in adapter does not
Consumable Materials align with guide hole in adapter,
(Ref. Section 910000) adapter must be replaced; otherwise
Item Nomenclature adapter may be reused.
CM318 Primer (6). Use 1/16 inch (0.0625) drill to drill
spring pin hole through adapter and
actuator; deburr hole.
(1). Remove actuator spring assembly.
(7). Reassemble actuator housing and trim
(2). Carefully drill out four rivets attaching tube.
trim tube. Remove trim tube. (8). Install actuator in housing. Screw
adapter on actuator.
(3). Remove actuator from actuator hous-
ing. Check housing for condition and (9). Support actuator shaft; press in spring
evidence of corrosion. pin. Ensure that pin is flush with shaft.
(10). Install actuator spring assembly.
NOTE: Housing may be either aluminum or
magnesium casting. (For corrosion control (11). Bench test actuator.
and identification of magnesium and alumi-
num alloys, Ref. Sec. 204000.) 28. Cyclic Trim Actuator Rework (Calco P/N
8222M6 and 8222M7)
(4). Use dimensions to assemble replace-
ment actuator housing and trim tube. If The following procedure is for tightening the
replacement part is undrilled, drill #40 trim actuator drive gear retention nut and also
0.098 inch (2.4892 mm) four attaching testing stalled actuators.
rivet holes. NOTE: Rework is NOT applicable to actuators
having letter "R" following vendor part
(5). Coat mating surfaces of trim tube and number on actuator housing.
actuator housing with primer (CM318).
Assemble while primer is still wet. (1). Remove cyclic trim actuator from
helicopter.
(6). Install four mechanically expanding
(2). If actuator is inoperative, bench test
rivets.
unit to determine whether mechanical
(stalled), electrical or other mechanical
(7). Reinstall actuator. failures exists.
(8). Reinstall actuator spring assembly. (a). A reading of 0.0 0.1 amperes
indicates electrical failure; replace
(9). Perform bench test. actuator.
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671000 Revision 31
MAINTENANCE MANUAL
(b). The motor runs, but the output shaft (4). Using fingers only, check gear drive
does not move, indicates a mechani- retention (hex) nut for looseness. If nut
cal failure; replace actuator. is loose, rework per instructions below.
If nut is NOT loose, replace actuator
(c). A reading of 0.7 amperes (approxi- assembly.
mately), or actuator extends part way
and stalls, indicates stalled failure; (5). Remove nut and clean threads. Rein-
rework actuator per steps (3). thru stall nut using Locktight #290 on
(9). below. threads. Torque nut to 30 40 inch
pounds (3.39 4.52 Nm).
(3). Remove lockwire and six screws (6). Reinstall actuator cover with existing
securing actuator cover to housing. screws; lockwire screws.
When removing housing, note (7). Add letter "R" at end of vendor part
CAUTION the location and number of number on actuator housing.
shims on each gear for reassembly in proper (8). As applicable, reinstall trim actuator.
location.
(9). Record rework of trim actuator in
NOTE: Step (4). not applicable if actuator is op- Components Record of helicopter Log
erative. Perform steps (5). thru (9). below. Book.
Page 816
Revision 21 671000
MAINTENANCE MANUAL
Section
671020
Collective and
Cyclic Stick Grips
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
COLLECTIVE AND CYCLIC STICK GRIPS

1. Collective Pitch Stick Switches provided at the left of the trim switch for
optional equipment. Coiled, insulated and
(Ref. Figure 201) The START, N2 GOV and openended wiring is provided in the grip for
LDG LT switches are on the collective stick connection to an optional switch.
assembly. Wiring for the switches is routed
down through the collective stick tube and NOTE: Cyclic stick grip configurations vary
interconnects with electrical system wiring and may have additional switches. Switch
through a connector at the base of the stick. functions are described in appropriate sec-
tions.
2. Collective Pitch Stick Switches
Replacement 4. Cyclic Control Stick Grip Replacement
(Ref. Figure 201) A. Cyclic Control Stick Grip Removal
(Ref. Figure 203)

(1). Disconnect removable contacts from
Item Nomenclature
electrical plug.
CM703 Tie strap
CM807 Twine, nylon (2). Remove nylon strap that secure wiring
to stick socket. Remove strap mounting
plate only if it is unserviceable.
Ensure all electrical power is
CAUTION OFF. (3). Remove screw from grip and separate
grip from tube.
(1). Disconnect grounding terminals.
(4). Tie a string to each wire bundle to aid
(2). Remove attaching hardware securing reassembly. Push wire slack into wiring
stick grip switch housing. Remove exit holes in stick socket while pulling
housing and switchplate. grip wiring from stick tube. Remove
grip and wiring; leave strings in tube.
(3). Disconnect wiring and remove affected
switch. B. Cyclic Control Stick Grip Installation
(4). Install replacement switch in reverse (Ref. Figure 203)

order of removal. If nylon strap
(CM703) is not available, use twine (1). Separate grip wiring into approximate-
(CM807) to secure wiring to collective ly equal size colorcoded bundles,
pitch stick. according to wiring diagram.
(5). Perform operational check of switch (2). Install an eight inch (20.32 cm) length
and associated system or equipment of AWG Size No. 3 electrical insulation
(Ref. appropriate PFM). sleeving on each bundle and push
sleeving up into grip.
3. Cyclic Stick Grip Switches
(3). Route wiring through stick tube and
(Ref. Figure 202) The pilots cyclic stick grip out wiring exit holes with aid of strings
contains a toggle switch for cyclic trim control inserted at stick removal. Push wires at
and a trigger switch for radio/interphone grip end while pulling slack out of
communications. A blank switch socket is socket.
Page 201
671020 Revision 21
MAINTENANCE MANUAL
KNOB
SETSCREW
PANEL NUT
LOCKWASHER
KNOB
SWITCH IDENTIFICATION
PANEL NUT PLATE
LOCKWASHER
CHECK NUT
N2 GOV SWITCH
(TYPICAL)
CHECK NUT
LANDING LIGHT
SWITCH
IDLE STOP RE-

LEASE SPRING SETSCREW
START SWITCH RETAINING RING

(HALF)
PILOTS STICK GRIP

SWITCH HOUSING
THROTTLE START SWITCH

SETSCREW (HALF)
SELFTAPPING SCREW
(SUPPIED WITH SWITCH)
IDLE STOP RE-

LEASE RING
G671027
Figure 201. Collective Pitch Stick Switch Replacement
Page 202
Revision 21 671020
MAINTENANCE MANUAL
SWITCH (S102)
(TOGGLE RED)
SWITCH (S4) *(S1)

(RED PUSHBUTTON WITH GUARD)
SWITCH (S103) *(107)

(TRIM BLACK)
SWITCH (S1) *(S4)

(RED PUSHBUTTON WITH GUARD)
SWITCH (S111) *(S112)

(ROCKER, (OLIVE)
SWITCH (S5)
(RED PUSHBUTTON WITH GUARD
TRIGGER SWITCH
WITH GUARD
VENDOR NAME AND

P/N IDENTIFICATION
STANDARD GRIP OPTIONAL T GRIP
NOTE:
OPTIONAL GRIP AN ASTERISK (*) INDICATES 3 VERSION
OF GRIP AND APPLICABLE SWITCH NUMBER.
G671028A
Figure 202. Cyclic Stick Grips
Page 203
671020 Revision 40
MAINTENANCE MANUAL
CYCLIC TRIM SWITCH (S107)

TRIGGER PIN
HOOK SWITCH (S4)
AND GUARD
FLOAT INFLATE/ HOIST

CUTTER SWITCH (S1/S5)
AND GUARD
XMIT/ICS TRIGGER
SWITCH (S112)
PLUG BUTTON
GRIP ASSEMBLY
G6710251
Figure 203. Cyclic Stick Grip Disassembly (Sheet 1 of 2)
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MAINTENANCE MANUAL
GRIP CAP
FOURWAY TRIM SWITCH

(S103) *(S107)
BUTTON
SWITCH TOGGLE SWITCH

(S1) *(S4) (S102)
RETURN SPRING
TRIGGER GUARD
PIN
PUSHBUTTON SWITCH
(S4) *(S1)
ROCKER SWITCH
(S111) *(S112)
TRIGGER SWITCH
(S101)
SWITCH (S5)
TRIGGER PIN
GRIP ASSEMBLY
NOTE:
ASTERISK (*) INDICATES 3 VERSION OF
GRIP AND APPLICABLE SWITCH NUMBERS.
OPTIONAL TGRIP
(P/N 369D297846)
G6710252
Figure 203. Cyclic Stick Grip Disassembly (Sheet 2 of 2)
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671020 Revision 21
MAINTENANCE MANUAL
(4). Install an additional eight inch 20.32 (6). Push slack wiring into wiring exit holes
cm) length of insulation sleeving to in stick socket while pulling grip wiring
protect each wire bundle where routed from stick tube.
through exit holes in socket.
(7). Remove trim switch cap by carefully
(5). Position grip on stick tube and install pulling cap off.
screw. (8). Remove all attaching hardware secur-
(6). Push as much wire slack as possible ing switches to grip, carefully remove
back into stick. Secure wiring to socket switches and attached harness from
with new nylon strap, or equivalent. grip assembly.
(9). Tag, identify and unsolder wires of
(7). Cut wiring to correct length and switch to be disconnected.
reinstall replaceable contacts and
electrical plug and wiring diagram. (10). Clean grip, wiring and switches with
alcohol (CM217).
5. Cyclic Stick Grip Switch Replacement
(11). Reconnect all electrical wires using
(Standard Grip)
solder (CM815), remove identification
(Ref. Figure 203) tags from wires.
(12). Carefully position switches to their
Consumable Materials approximate location within the grip.
(Ref. Section 910000) NOTE: Ensure that switches are correctly posi-
Item Nomenclature tioned with any applicable keyway, pin hole,
CM217 Isopropyl alcohol etc, for proper alignment of mating parts.
(13). Install attaching hardware securing
CM703 Tie strap switches onto grip.
CM815 Solder
(14). Install trigger and trigger attach pin.
(15). Install cyclic trim switch cap.
Ensure that all electrical
WARNING power is OFF. (16). Reinstall grip on stick tube, route grip
wiring through stick tube and attach
(1). Disconnect cyclic grip wiring connector connector.
from plug at lower end of cyclic stick.
(17). Check switch operation and wiring
(2). Remove strap securing wiring to stick continuity.
socket; remove strap mounting plate if
it is unserviceable. (18). Apply sealing compound (CM425) to all
screw holes and insert holes.
(3). Remove exterior sealant from grip
(19). Secure wiring to stick with nylon straps
assembly covering switch mounting
(CM703).
hardware and attaching screws.
Cyclic trim actuators should be
(4). Drive trigger pivot pin from grip to CAUTION operated only momentarily to
release trigger. Pin is removed from prevent damage to equipment.
right to left while holding grip in
normal position. Remove trigger. (20). Check operation of switch by momen-
tarily cycling in all modes ensuring that
(5). Remove screw from grip and separate the associated system operates correct-
grip from stick tube. ly.
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MAINTENANCE MANUAL
6. Cyclic Stick Grip Disassembly (Optional cal wires using solder (CM815) and
TGrip, PN 369D297846 Only) reinstall switches as applicable.
(Ref. Figure 203) NOTE: Ensure that switch is correctly posi-
tioned with any applicable keyway, pin hole,
Ensure that all electrical etc, for proper alignment of matching parts.
WARNING power is OFF.
(2). Insert replacement switch at the
(1). Remove the grip cap by removing six approximate mounting position on the
screws. grip subassembly.
NOTE: The grip is to be disassembled only to (3). Using solder (CM815), connect wiring
the extent required for replacement of the to terminals of the replacement switch.
switches. The wiring through the grip as- Remove identification tags from wires.
sembly is tied with nylon twine and covered NOTE:
with a two inch (5.08 cm) insulating sleeve.
Do not remove the twine and sleeves unless D Helicopters (369D) S/N 003 thru 480 may
wire replacement is required. require trigger switch rework to accom-
modate replacement switch (Ref.
(2). Detach the rocker switch (S111) by Figure 204).
removing two screws. D Rework is not necessary for the following
(3). Unscrew the trigger pin and carefully cyclic grip assemblies; PN 369D27133 or
withdraw it while holding the trigger A21896440100.
guard and trigger switch (S101) in (4). If rework is required, perform steps (a).
place. Then remove the trigger guard thru (c). before continuing.
and switch and separate them with care
to prevent distorting or losing the (a). Press or pull insert from top of grip.
return spring. (b). Make template of profile of new
(4). Remove toggle switch (S102). Switch A21815869805 trigger switch.
button is separated from housing by (c). Using file, blade or equivalent
pressing out the pin. routing tool, remove material from
lower inside edge of hole for trigger
(5). Unsolder wiring connected to terminals
switch to permit installation of new
on the switch to be disconnected. Tag
switch. Use template to determine
and identify wires to facilitate correct
amount and location of material to be
reconnection.
removed.
7. Cyclic Stick Grip Reassembly and (5). As applicable, secure or attach the
Modification trigger switch, (trigger guard and
return spring for 369D297846 cyclic
(Ref. Figure 203 and Figure 204) grips) to the grip housing using the
original attaching hardware.
(6). Apply sealing compound (CM425) to all
open screw holes and insert hole.
Item Nomenclature
CM217 Isopropyl alcohol (7). Secure the grip cap (for 369D297846
CM314 Varnish, moisture resistant cyclic grips) to the grip subassembly
with six screws; coat the screws with
varnish (CM314) before installation
CM703 Tie strap into grip.
CM815 Solder
(8). Reinstall grip on stick tube. Using
attached strings, route grip wiring
(1). Clean grip, wiring and switches with through stick tube and reconnect at
alcohol (CM217). Reconnect all electri- electrical plug.
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MAINTENANCE MANUAL
(9). Check switch operation and wiring Cyclic trim actuators should be
continuity. CAUTION operated only momentarily to
prevent damage to equipment.
(10). Secure wiring to stick socket with nylon (12). Check operation of the switch by
strap (CM703). momentarily activating it and ensuring
that the associated system operates
(11). Energize the electrical system. correctly.
REMOVE THIS INSERT
A21815869805 SWITCH
REOMOVE MATERIAL HERE
NOTE:
TRIM INSIDE EDGE OF CYCLIC GRIP AS REQUIRED
FOR INSTALLATION OF NEW TRIGGER SWITCH.
G671026
Figure 204. Rework of Cyclic Stick Grip
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MAINTENANCE MANUAL
Section
672010
AntiTorque Flight
Controls (Two and
Four Blade)
(369D/E/FF)
MAINTENANCE MANUAL
ANTITORQUE FLIGHT CONTROLS

(TWO AND FOUR BLADE)
1. Tail Rotor Control Configuration control pedals with left copilots dual
controls. Foot rest not installed.
The helicopter may be equipped with either of
two basic pilots tail rotor foot pedal control
configurations. The tail rotor and control 2. Upper Fuselage and Tailboom Control
linkage to the foot pedals are identical on Linkage
either basic configuration.
(1). Basic LeftHand Command Tail Rotor Upper fuselage tail rotor controls consist of
Controls. Single left position pilots tail Sta. 95 bellcrank and support at the front of
rotor control pedals. Foot rest can be the main rotor mast base, Sta. 120 control rod
installed at right side of crew compart- and Sta. 142 bellcrank inside the boom fairing.
ment in place of righthand foot pedals. Boom linkage consists of tailboom control rod,
supported by seven bushings (grommets), and
(2). Basic RightHand Command Tail Rotor Sta. 284 Bellcrank mounted on the tail rotor
Controls. Right position pilots tail rotor transmission.
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672010 Revision 21
MAINTENANCE MANUAL
PITCH CONTROL ASSEMBLY
CONTROL ROD BUSHING

(GROMMET) (7 PLCS)
TAILBOOM CONTROL ROD STA. 284
BELLCRANK
TAIL ROTOR ASSEMBLY
STA. 95 BELLCRANK
BOOT
STA. 120 CONTROL ROD
TAIL ROTOR CONTROL SUPPORT

RIGHT POSI-
TION FOOT STA. 78.50 (TUNNEL
REST ROUTED) CONTROL ROD
IDLER BELLCKRANK
PEDAL FLOOR
ROUTED CON-
TORQUE TUBE TROL ROD
MOUNTING BRACKET
TORQUE TUBE LEFT POSITION PED-

AL MOUNTING
BRACKET
G670001A
Figure 101. Tail Rotor and Control System
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MAINTENANCE MANUAL

1. Sta. 120 Control Rod or Sta. 142 Bellcrank (2). Ensure that slotted bushings are in
Replacement place at each end of bellcrank; then
position riveted rod end in bellcrank
A. Sta. 120 Control Rod or Sta. 142 and install bolt, two washers, nut and
Bellcrank Removal cotter pin. Make sure that hump of
bellcrank faces forward.
(Ref. Figure 401) The Sta. 142 bellcrank and
Sta. 120 control rod must be removed as an (3). Carefully feed assembled control rod
assembled unit. and bellcrank through forward air
(1). Remove tail rotor control bellcrank intake at left side of control mixer
access door from left side of boom installation while an assistant guides
fairing. the assembly through boot support tube
to bellcrank support bracket.
(2). Disconnect tailboom control rod from
lower end of Sta. 142 bellcrank. (4). Position rubber boot in place at Sta.
137.50.
(3). Remove hardware that secures Sta. 142
bellcrank to boom fairing brackets. (5). Position Sta. 142 bellcrank in support
bracket and install bolt, two washers,
(4). Open hingemounted access door on nut and cotter pin.
engine air inlet aft fairing. Remove
clamp on boot support tube at Sta. Check Sta. 142 bellcrank for
137.50. CAUTION clearance with support struc-
(5). Disconnect forward end of Sta. 120 ture. Pay particular attention to area above
control rod from Sta. 95 bellcrank. 369A795123 bearing when top of bellcrank
is in forward position. If contact is noted,
NOTE: Sta. 95 bellcrank must also be detached machine surface of bellcrank (machine sur-
from its support for clearance from air inlet face with interference only) (Ref.
fairing for rodend bolt removal. Figure 801).
(6). Carefully pull forward end of control (6). Check that slotted bushing is in place
rod and withdraw assembled rod and in Sta. 95 bellcrank; then install
bellcrank out through boot support tube forward rod end in bellcrank with bolt
at plenum chamber Sta. 137.50. (head to left), two washers, nut and
cotter pin.
(7). Disconnect control rod from upper end
of bellcrank. (7). Reinstall Sta. 95 bellcrank in its
support with bolt, two washers, nut and
B. Sta. 120 Control Rod or Sta. 142
cotter pin.
Bellcrank Installation
(Ref. Figure 401) Sta. 142 bellcrank and Sta. (8). Secure rubber boot at support tube with
120 control rod must be installed as a unit by nylon strap. Then clamp tail rotor
routing assembled end of bellcrank and control pedals in neutral, set free length of
rod through boot support tube at plenum bellows portion of boot at approximately
chamber station (Sta. 137.50). 5.5 inches and secure end to control rod
with nylon strap.
(1). For access to bellcrank support bracket,
use access door in boom fairing. (9). Check rigging of tail rotor controls.
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672010 Revision 21
MAINTENANCE MANUAL
NOTE 2
STA. 137.50
BUSHING (GROMMET)
(7 PLACES) BOOT
* STA. 142 BELLCRANK
NYLON
NOTE 2 BEARING
STRAP STATION 284
STA. 120 CON- BELLCRANK PIVOT PIN
TROL ROD
(NOTE 1) SPECIAL
WASHER
* STA. 95 BELLCRANK
* SUPPORT
NOTE 2
WASHER
TAILBOOM CON- (NOTE 5)
TROL ROD
(NOTE 3)
MAXIMUM ALLOWABLE
LOOSENESS 0.040 IN.
BEARING
(1.016 MM)
BEARING
RIVET ADAPTER
RIVET A
ROD LENGTH AND BEARING

ANGULARITY BEFORE RIG
CONTROL DIMENSION
ANGLE
ROD L
A
NOTES: INCHES (CM)
1. MINIMUM OF 0.060 IN. (1.524 MM) CLEARANCE FOR FULL RANGE OF 45.88 (116.5352)
STA. 120 IN LINE
TRAVEL THRU STA. 137.50 BULKHEADS.
2. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TAILBOOM 143.80 (365.252) 63
TO A MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE SURFACE OF
PART AFTER NUT IS TIGHTENED.
3. MINIMUM OF 0.010 IN. (0.254 MM) CLEARANCE FOR FULL RANGE OF
TRAVEL BETWEEN BOOM AND TAIL ROTOR TRANSMISSION.
4. ASTERISK ( * ) INDICATES PARTS THAT MAY BE EITHER ALUMINUM OR
MAGNESIUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
CONTROL (REF. SEC. 204000).
5. ADD ONE OR TWO AN960KD516 WASHERS AS REQUIRED FOR CLEARANCE
AT PEDAL FULL STROKE.
G672000B
Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage
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MAINTENANCE MANUAL
2. Sta. 284 Bellcrank Replacement (4). Slowly pull aft end of control rod and
withdraw rod through opening in tail
A. Sta. 284 Bellcrank Removal rotor transmission mounting frame.
(Ref. Figure 401) B. Tailboom Control Rod Installation
(1). Disconnect bellcrank from tailboom (Ref. Figure 401)

control rod.
NOTE: Tailboom control rod is routed through
boom with forward rod end removed.
(2). Disconnect bellcrank from tail rotor
transmission. Disengage bellcrank
(1). Deleted
pitch control pin from pitch control
housing and remove bellcrank.
(2). Guide control rod through boom aft
frame opening and carefully route
B. Sta. 284 Bellcrank Installation through seven bushings (grommets).
Rotate rod slightly to start it through
(Ref. Figure 401) each grommet.
(1). Insert bellcrank pivot pin into pitch (3). Check that slotted bushing is in place
control housing selfaligning bearing. in lower lug of Sta. 284 bellcrank; then
attach aft rod to bellcrank.
(2). Position bellcrank to align with mating
hole in tail rotor transmission arm and (4). Using measurement recorded at time of
install bolt. rod removal, install forward rod end
bearing. Align rod ends so that bearings
(3). Check that slotted bushing is in place have equal space for angular throw;
in lower lug of bellcrank; then attach hold rod end and tighten jam nut.
tailboom control rod to bellcrank with
bolt, two washers, nut and cotter pin. (5). Check that slotted bushing is in place
in lower end of Sta. 142 bellcrank; then
(4). Check rigging of tail rotor controls (Ref. attach forward rod end to bellcrank.
Tail Rotor Controls Rigging).
(6). Check rigging of tail rotor controls (Ref.
3. Tailboom Control Rod Replacement
(7). Close plenum chamber access door.
A. Tailboom Control Rod Removal
4. Sta. 95 Bellcrank and Support
(Ref. Figure 401) Replacement
(1). Disconnect control rod from Sta. 284 A. Sta. 95 Bellcrank and Support Removal
bellcrank.
(Ref. Figure 401)
(2). Remove tail rotor control bellcrank
access door from left side of boom (1). Disconnect tunnelrouted control rod
fairing. from bellcrank.
(3). Accurately measure and record distance (2). Disconnect bellcrank from support.
between unchamfered edge of forward
rod end bearing jam nut and center of (3). Disconnect bellcrank from Sta. 120
bearing attach bolt hole. Hold forward control rod and remove bellcrank.
rod end, loosen jam nut and unthread
control rod from rod end by turning aft (4). Remove hardware that secures support
end of rod. to mast structure; remove support.
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MAINTENANCE MANUAL
INITIAL CONTROL ROD LENGTH

BEFORE RIG
STA. 95 BELLCRANK
CONTROL DIMENSION L
ROD INCHES (CM)
TUNNELROUTED 57.95 (147.193)
FLOORROUTED 30.06 (76.3524)
RIVET STA. 97.50 (TUN-

NELROUTED) CON-
TROL ROD
L CONTROLS SUPPORT
MAXIMUM ALLOWABLE LOOSE-
NESS 0.040 IN. (1.016 MM) BRACKET
SPRING FITTING
AFT EYEBOLT TAIL ROTOR
STA. 63.00 BUNGEE IDLER BELLCRANK
SPRING NOTE 2
FORWARD EYEBOLT
NOTE 1 FLOORROUTED
CONTROL ROD
NOTE 2
NOTE 3
TORQUE TUBE BUSHING ASSY
(NOTE 4)
* TORQUE TUBE BRACKET NOTE 1 NOTE 3
(NOTE 5)
CONTROL ROD FITTING
PIN NOTE 1
WASHER
NOTE 4
BEARING NOTE 1
* LEFT PEDAL
STOP BOLT BEARING
* RIGHT PEDAL
JAMNUT
NOTE 2
NOTE 3
NOTE 1
* PEDAL ARM
NOTE 1 * PEDAL BRACKET
BUSHING (TEF-
LONLINED) * PEDAL ARM
NOTE 4
NOTE 2
NOTES:
BUSHING (TEF- 1. SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416
LONLINED) AND/OR 416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN
0.010 IN. (0.254 MM).
BUSHING ASSY 2. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN.
(NOTE 4) LINK
(0.254 MM) TO A MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE
NOTE 2
SURFACE OF PART AFTER NUT IS TIGHTENED.
NOTE 2 3. DIRECTION OF BOLTS IS OPTIONAL.
BEARING 4. ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF
BELLCRANK 0.002 INCH (0.051 MM) AT EACH END.
5. INSTALLED WITH BEARING RECESS FACING FITTING.
6. ASTERISK (*) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR
ALUMINUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
CONTROL (REF. SEC. 204000).
G6720011C
Figure 402. Tail Rotor Pedal Installation (Sheet 1 of 2)
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MAINTENANCE MANUAL
STOP BOLT (2)
NOTE 1
NOTE 2
JAMNUT
ADJUSTABLE BUSH-
ING ASSEMBLY
(NOTE 4)
NOTE 3
TORQUE TUBE
SLOTTED BUSHING
(TYPICAL) (NOTE 2)
SLEEVE TORQUE TUBE
ADJUSTABLE BUSH-
ING ASSEMBLY
(NOTE 4)
RIGHT POSITION TAIL ROTOR PEDALS G6720012A
Figure 402. Tail Rotor Pedal Installation (Sheet 2 of 2)
B. Sta. 95 Bellcrank and Support Installation C. Tail Rotor Pedal Assembly General
(1). Install bellcrank support to mast (Ref. (Ref. Figure 402) Tail rotor pedal
structure with three bolts, seven installation consists of a pair of adjustable
washers and three nuts. Forward bolt pedals, pedal arms with interconnecting
requires an extra washer under linkage, pedal mounting bracket for left
bolthead; two thin washers are used at control position, torque tube with control rod
all three locations. Torque nuts to 80 fitting and torque tube mounting bracket.
100 inchpounds (9.04 11.30 Nm). Forward pressure on right pedal rotates torque
tube, moving control system linkage to
(2). Check that slotted bushings are in increase tail rotor blade pitch. Pressure on left
place in bellcrank; then attach Sta. 120 pedal decreases tail rotor blade pitch. A
control rod to bellcrank with bolt (head bungee spring is installed at aft end of
to left). floorrouted control rod in underseat tail rotor
(3). Install bellcrank in support. control linkage. This spring relieves left pedal
forces during flight and causes left pedal to
(4). Attach tunnelrouted control rod to remain at forward position when helicopter is
bellcrank. on ground and not operating.
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MAINTENANCE MANUAL
NOTE: Parts identified with an asterisk (*) simplify torque tube alignment during
may be either magnesium or aluminum reinstallation.
alloy. (Ref. Sec. 204000 for corrosion con-
trol and identification of magnesium and (10). Remove four nuts, eight washers, any
aluminum alloys). shim washers and four bolts that secure
pedal bracket to bulkhead. Remove
D. CoPilots Pedal Installation control pedal installation. Keep shim
washer selection with bracket.
(Ref. Figure 402) The copilots pedal installa-
tion is essentially the same as the pilots. A B. Tail Rotor Pedal Assembly Installation
sleeve couples a torque tube extension to the (Ref. Figure 402)
pilots torque tube. Dual pedal installation is
also equipped with pedal stop nuts, heel strips, NOTE: Install both left and right pedal brack-
retaining springs and attachment hardware. ets for righthand command helicopters.
5. Tail Rotor Pedal Assembly Replacement (1). Install pedal bracket with four bolts,
eight washers and four nuts. Add shim
A. Tail Rotor Pedal Assembly Removal washers as required at pedal bracket
attachment points to keep centerline
(Ref. Figure 402) alignment of pedal bracket bearings
within 0.010 inch (0.254 mm). Correct
(1). Pull two hinge pins from pilots com- alignment is indicated by free rotation-
partment floor access door hinges and al movement of torque tube after nuts
remove door. Remove access panel from are tightened.
each side of instrument panel lower
support structure. (2). Position torque tube bracket over
mating holes in bulkhead and check
(2). Remove battery (Ref. Chap. 96). alignment with bulkhead. Add shim
washers as required at bracket attach-
(3). Remove pins securing pedals to pedal ment points to maintain bearing
arms and remove pedals. alignment established in step a above.
(4). For access to bungee, remove access Install two bolts, four washers and two
cover between pilots seats and/or by nuts.
removing left passengers footwell on (3). Install forward eyebolt, using same
aft side of canted bulkhead. number of washers removed, on bungee
(5). Block left tail rotor control pedal at full and then hook aft end of bungee into
forward position to relieve tension on eyebolt on floorrouted control rod
bungee. fitting.
NOTE: If tail rotor pedal forces are not zero
(6). Remove eyebolt and washers at Sta. 63 during level flight at 130 to 140 knots, tail
with bungee attached. Keep washers rotor force adjustment may be accomplished
with eyebolt for reinstallation. by removing washers as required from the
(7). Disconnect bungee from eyebolt and eyebolt at Sta. 63 bracket.
fitting at aft end of floorrouted control (4). Using spring tension tool install bungee
rod by using spring tension removal into position at Sta. 63 bracket; install
tool (75, Table 203, 9100). washer and nut on eyebolt.
(8). Remove cotter pin, nut, two washers (5). Check that slotted bushing is in place;
and bolt that connect floorrouted then install floorrouted control rod in
control rod to torque tube fitting. torque tube fitting and install bolt, two
washers, nut and cotter pin.
(9). Remove two nuts, four washers, any
shim washers and two bolts that secure (6). Check rigging of tail rotor controls and
torque tube bracket to bulkhead. Keep pedaltocanopy clearance (Ref. Tail
shim washer selection with bracket to Rotor Controls Rigging). Pedals should
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Revision 21 672010
MAINTENANCE MANUAL
clear windows by a minimum of 0.20 (5). Check that spherical bearings are in
inch (5.08 mm) with 20 pounds (88.96 place; then attach bellcrank to pedal
N) of force applied. bracket with bolt, two washers, nut and
cotter pin.
6. Dual Tail Rotor Pedal Initial Installation
(6). Check that slotted bushings are in
place; then fasten each link to bellcrank
(Ref. Figure 402)
with bolt, two washers, nut and cotter
pin.
NOTE: Before pedal installation, remove the
bushing assembly that secures pilots left (7). Check that slotted bushings are in
pedal arm to the torque tube. This will allow place; then fasten each link in pedal
the tube to rotate far enough to install the arm lugs with bolt, two washers, nut
bushing assemblies. and cotter pin.
(1). Thread a stop nut on each of the two (8). Install pedal bracket assembly with
stopbolts and install bolts into four bolts, eight washers and four nuts.
threaded inserts of pedal bracket. Add shim washers as required at pedal
bracket attachment points to keep
(2). Locate pedal bracket and pedal arms centerline alignment of pedal bracket
for correct position on torque tube. bearings within 0.10 inch (2.54 mm).
Correct alignment is indicated by free
(3). Fasten left pedal arm to torque tube rotational movement of torque tube
with adjustable bushing assembly; after nuts are tightened.
install bushing bolt so that shank of the
bolt head end protrudes at least 0.002 (9). Reinstall bushing assembly previously
inch. Install nut and torque to 80 removed from the pilots left pedal arm.
inchpounds (9.04 Nm) plus drag (10). Install pedals on pedal arms and secure
torque, do not allow bolt to turn. with pins provided.
(4). Check that each end of bushing pro- (11). Install heel strips with pins, washers
trudes at least 0.002 inch (0.051 mm). If and cotter pins. Direction of pin head is
not, loosen nut and repeat prior step. optional.

672010 Revision 21
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Tail Rotor Controls Rigging (b). Sta. 95 bellcrank: Centerline of
tunnelrouted control rod attach bolt
(Ref. Figure 501) The tail rotor control system should be 4.30 0.090 inches (109.22
must be rerigged immediately after replace- 2.286 mm) above mast base struc-
ment of linkage that cannot be accurately ture.
measured (by trammeling, etc) before it is (c). Sta. 142 bellcrank: Centerline of
installed in the tail rotor control system, or if tailboom control rod attach bolt
helicopter operation reveals a rigging deficien- should be 4.755.09 inches
cy. (120.65129.286 mm) from aft face of
Sta. 137.50 bulkhead. For access to
bellcrank, remove tail rotor control
Special Tools bellcrank access door.
Item Nomenclature (3). Loosen rod end jam nut at forward end
of tailboom control rod.
ST606 T/R swashplate rigging tool
(4). On tail rotor transmission, remove
hardware attaching tailboom control
Remove pilots pedals and copi- rod to inboard end of Sta. 284 bellcrank.
CAUTION lots (if installed) to prevent pos-
(5). Tie back tail rotor rotating boot. Place
sible contact with lower windshield during
midtravel portion of swashplate rigging
rigging sequence.
tool (ST606) between swashplate and
tail rotor fork splitring retainer (B,
NOTE: Control rod end bearing adjustments Figure 501). Make sure that rigging
are to be made to nearest half turn that pro- tool contacts ring and not fork.
duces correct rigging. When tightening jam
nut at adjustable end of a control rod, al- (6). Turn tailboom control rod at aft end.
ways hold rod end with a wrench to prevent Adjust rod length to nearest half turn of
jamming of bearing. Never reinstall a used rod end that allows swashplate rigging
cotter pin; always install a new one. tool to just slide between splitring
retainer and swashplate.
(1). Disconnect bungee spring at aft end of (7). Recheck that centerline of tailboom
floorrouted control rod (Ref. control rod forward attach bolt remains
Figure 402). 4.755.09 inches (120.65129.286 mm)
from aft face of Sta. 137.50 bulkhead.
(2). Using two pieces of wood and Cclamp Also check forward rod end for not less
or rope, secure pilots foot pedal arms so than one and onehalf exposed threads
they are aligned (A, Figure 501). With with jam nut snug against rod. If either
pilots foot pedals clamped in neutral condition does not exist, disconnect
and control rod lengths adjusted (Ref. forward end of Sta. 120 control rod and
Figure 401 and Figure 402), control readjust both control rods until Sta. 142
system bellcrank positions may be bellcrank position and exposed threads
checked as follows: of both control rods are within toler-
ance.
(a). Tail rotor idler bellcrank (pilots (8). Ensure that slotted bushing is in place
compartment): Centerline of aft arm in bottom ear of Sta. 284 bellcrank and
should be 90 2 degrees to Sta. 78.50 inboard ear of Sta. 95 bellcrank.
bulkhead. Connect control rods (Ref. Figure 401).
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0.250 IN. (6.35 MM)

MAX. MISALIGNMENT NOTES:
BETWEEN PEDALS 1. ROTATING BOOT NOT SHOWN. NORMALLY IT
IS TIED BACK TO LOCATE RIGGING TOOL.
2. TAILBOOM CONTROL ROD AND STA. 120 CONTROL
CLAMPING BLOCKS ROD LENGTHS ARE ADJUSTED FOR CORRECT
MIDTRAVEL RIGGING.
3. ST606, TABLE 3, SEC. 910000
STOP NUT
RIGHT STOP BOLT
LEFT STOP BOLT
PEDAL ARM ALIGNMENT AND

STOP BOLT ADJUSTMENT
SWASHPLATE
NONROTATING RIGGING TOOL
BOOT (NOTE 3)
TAILBOOM CONTROL ROD

(NOTE 2) TAIL ROTOR FORK SPLITRING
RETAINER
BELLCRANK ACCESS DOOR
STA. 120 CONTROL ROD

(NOTE 2) MIDTRAVEL RIGGING
(NOTES 1, 2)
LEFT PEDAL RIGGING RIGHT PEDAL RIGGING
G672002B
Figure 501. Rigging Tail Rotor Control System
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MAINTENANCE MANUAL
(9). Check witness holes for proper thread (15). Operate pedals through full range of
engagement. Align rod ends to get travel. While controls are being moved,
approximately equal angular throw in check that there is never less than
bellcranks; tighten jam nuts. 0.060 inch (1.524 mm) clearance around
Sta. 120 control rod where it passes
(10). Remove clamping device from foot pedal through structure at Sta. 137.50 and
arms. that there is never less than 0.010 inch
(0.254 mm) clearance around tailboom
control rod where it exits between boom
(11). Loosen jam nuts on pedal stop bolts (A,
and tail rotor transmission.
Figure 501). Screw in pedal stop bolts
approximately 0.50 inch (12.70 mm).
(16). Connect bungee spring between aft end
of floorrouted control rod and Sta. 63
Use care when actuating pedals
CAUTION to avoid possibility of damaging
bracket (Ref. Figure 402) and check
that pilots left pedal moves to its
tool or windshield. normal forward position.
NOTE: Adjust copilots pedal stop bolts to (17). Install Sta. 142 bellcrank access door.
match pilots pedal travel, 0.0010.003 inch
(0.0250.076 mm) gap between stop bolts
and pedals. 2. Tail Rotor Bungee Adjustment

(12). Adjust right pedal stop bolt (A,
Figure 501) so that when pedal arm is
held against stop, right pedal portion of (1). 2Bladed bungee adjustment:
swashplate rigging tool just slides
between splitring retainer and (a). Increase pedal force by removing
swashplate (view C). Fit should be tight washers from under bungee spring
enough to support weight of tool. eyebolt.
Without changing adjustment of bolt or
tool fit, tighten jam nut on stop bolt. (b). If tail rotor pedal forces are not zero
during level flight at 130 140 knots,
(13). Adjust left pedal stop bolt (A, tail rotor force adjustment may be
Figure 501) so that when pedal arm is accomplished by removing a desired
held against stop with 20 25 pounds number of AN9703 washers.
(88.96 111.20 N) pressure (or pull on
right pedal), left pedal portion of (2). 4bladed bungee adjustment:
swashplate rigging tool just slides
between splitring retainer and (a). Adjust tail rotor pedal force by
swashplate (view D). Fit should be tight tightening or loosening the 0.120
enough to support weight of tool. inch (3.048 mm) thread adjustment
Without changing adjustment of bolt or on bungee female bearing assembly.
tool fit, tighten jam nut on stop bolt.
Remove swashplate rigging tool and (b). Tighten to maximum 0.120 inch
restore rotating boot to normal installed (3.048 mm) thread adjustment on
position. bungee female bearing assembly
increases pedal force approximately
(14). Reinstall pedals. Slowly press outboard five pounds; loosening decreases
pedal to its full forward travel position pedal force.
against stop bolt. With not more than
20 pounds pressure applied, upper and (c). Bungee spring may be attached to
lower edges of pedal must clear canopy any of four holes in fitting. If exces-
glass by not less than 0.20 inch (0.508 sive left pedal force is required,
mm). position spring at lower hole.
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MS24665143
COTTER PIN
AN42BC10A EYEBOLT BUNGEE
STA. AN9703 WASHER (8 REQUIRED) ASSEMBLY
63.00 MS210423 NUT
369A2541 AN96010L WASHER
BRACKET
MS178264
NUT
AN960KD416L
WASHER
AN960KD416L
WASHER
NAS110411D
BOLT
369D27521 369DSK8319
SPRING FITTING
TAIL ROTOR BUNGEE TAIL ROTOR BUNGEE

(2BLADED) (4BLADED)
G672019
Figure 502. Tail Rotor Bungee Adjustment
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INSPECTION/CHECK
1. Upper Fuselage and Tailboom Control 2. Tail Rotor Pedal Assembly Inspection
Linkage Inspection
(Ref. Figure 402)
(Ref. Figure 401)
(1). Inspect rod end bearings for binding NOTE: Inspect components at left and right po-
and excessive wear, 0.040 inch (1.016 sition on the righthand command models.
mm) maximum axial play. Inspect rivet Check that corresponding pedals contact
at fixed rod end. stops simultaneously.
(2). Inspect control rod for surface damage
(1). Inspect pedals and pedal arms for
and evidence of bending.
cracks, elongated pedal attach holes
(3). Inspect rubber boot just forward of Sta. and open drain holes. Inspect teflon
137.50 bulkhead for condition. reinforced bushing liners for deteriora-
tion.
(4). Inspect tailboom control rod surfaces
that pass through all grommets. (2). Inspect pedaltoarm quickrelease
Serviceable wear is limited to thickness locking pin for condition and positive
of hard anodic coating. Check that all spring action.
bushings are secure.
(5). Inspect bellcranks for scratches, cracks, (3). Inspect links and bellcrank for cracks
corrosion and similar surface defects. and bends, and bearings for excessive
play.
(6). Inspect bellcrank bearings for looseness
and binding. (4). Inspect control rod fitting, torque tube
(7). Inspect for obstructions in drain slot of mounting bracket and pedal mounting
Sta. 284 bellcrank. bracket for cracks and corrosion. Using
an 8power magnifying glass, mirror
(8). Inspect for corrosion or excessive wear and flashlight, closely inspect pedal
on Sta. 284 bellcrank pivot pin. link bellcrank fitting of pedal bracket in
center forward area where fitting (fork
(9). Visually inspect doublers on Sta. 142 piece) joins tubular section. If any
bellcrank supports for cracking/da- cracks are detected, replace bracket
mage. assembly. Inspect bracket bearings for
NOTE: MDHC Notice DN49 contains infor- excessive looseness.
mation relative to repair of damaged dou-
blers on bellcrank supports. MDHC Notice (5). Inspect torque tube for cracks,
DN102 contains information required to scratches, nicks, dents and similar
modify the particle separator fairing and surface defects.
cover assemblies to prevent possible chafing
of the Sta. 120 tail rotor control rod. (6). Inspect pedal brackets for corrosion.
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Table 601. Isolating Control System Troubles

Binding, lockingup and erratic Disconnect pitch control links from If symptom is gone, replace tail rotor
action of foot pedals (Do not force pitch control assembly. assembly. Repair (Ref. COM).
controls).
Symptom remains. Disconnect Sta. 284 aft boom If symptom is gone, clean
bellcrank from pitch control swashplate bore and output shaft
assembly. splines. Lubricate splines. Replace
swashplate if necessary. Check for
elongation of bolt hole in support arm
portion of main housing assembly of
tail rotor gearbox, caused by
looseness of bellcrank fulcrum bolt
and nut. Repair (Ref. COM).
Symptom remains. Disconnect floorrouted tail rotor If symptom is gone, inspect tail rotor
control rod from foot pedal torque control rods and bellcranks until
tube fitting. defective part is located.
Symptom remains. Loosen foot pedal torque tube If symptom is gone, pedal torque
brackets mounted on front of floor tube misaligned; shim for correct
structure. alignment. If symptom remains,
disassemble and inspect tail rotor
control foot pedal installation until
Trouble corrected.
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REPAIRS
1. Floor and TunnelRouted Control Rods (5). If removed, install rivet to secure rod
end.
(Ref. Figure 401 and Figure 402) The floor
and tunnelrouted control rods connect the tail (6). Check that slotted bushing is in place;
rotor pedal installation with the upper then secure control rod in torque tube
fuselage and tailboom control linkage. The two fitting or idler bellcrank with bolt, two
control rods are linked by a tail rotor idler washers, nut and cotter pin.
bellcrank mounted on the underseat controls
support bracket. (7). Install bungee spring.
(8). Install access doors.
2. FloorRouted Tail Rotor Control Rod
Repair (9). Check rigging of tail rotor controls (Ref.
(Ref. Figure 401) Replace rod end if bearing
axial play is more than 0.040 inch (1.016 mm). 3. Upper Fuselage and Tailboom Control
Riveted rod end bearing is replaceable without Linkage Repair
rod removal if located at forward end of rod. If
riveted rod end is aft, rod removal is required (Ref. Figure 401)
to replace rod end bearing.
NOTE: Floorrouted control rod normally does (Ref. Section 910000)
not require replacement unless helicopter Item Nomenclature
receives extensive impact or crash damage.
Remove control rod forward through land- CM318 Primer
ing light wiring grommet hole after landing CM431 Sealing, locking and retaining compound
light (if installed) is removed (Ref. Chap. CM802 Abrasive cloth, aluminum oxide
96).
(1). Disconnect control rod from pedal (1). Perform straightness check on control
torque tube fitting or from tail rotor rod that appears bent or bowed. Total
idler bellcrank (Ref. Figure 402). length of Sta. 120 control rod, excluding
Remove bungee spring (Ref. Sec. rod ends, must be straight within 0.040
671000). inch (1.016 mm), with straightness
variation limited to maximum of 0.010
(2). Accurately measure and record distance inch (0.254 mm) in each foot of length.
between unchamfered edge of rod end Total length of tailboom control rod,
jam nut and center of rod end bearing excluding rod ends, must be straight
hole. within 0.120 inch (3.048 mm), with
straightness variation limited to
Use care when drilling to re- maximum of 0.010 inch (0.254 mm) in
CAUTION move or install riveted rod end; each foot of length.
rod end is steel and rod is aluminum.
A dye check for cracking
(3). If necessary, drill out rivet. Loosen jam WARNING must always be performed
nut and unscrew rod end. after coldstraightening. Replace
cracked rod, or cracked or bent rod
(4). Screw another rod end into rod to end.
obtain same measurement made in step
(2). above. Align control rod ends so (2). Coldstraighten bent rod that is not
that bearings have equal space for within tolerance (step (1). above)
angular throw; tighten jam nut. provided there are no nicks or sharp
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672010 Revision 21
MAINTENANCE MANUAL
dents in bend length. Do not use rod (6). Repair minor surface defects such as
ends to support rod during straighten- scratches, nicks and corrosion on
ing process. bellcranks and support bracket. Use
abrasive cloth, grade 400 600
Use care when drilling to re- (CM802), to smooth out and blend in
CAUTION move or install riveted rod end; such defects. Following rework limits
rod end is steel and rod and bearing adapter represent total limits, including effects
are aluminum. of all previous repairs to any given
area.
play is more than 0.040 inch (1.016 NOTE: Parts identified (Ref. Figure 401) with
mm). Set initial control rod length and an asterisk ( * ) may be either magnesium or
bearing angularity. aluminum alloy. For corrosion control and
identification of magnesium and aluminum
(4). Replace unserviceable control rod alloys, refer to Section 204000.
bearing adapter. Trammel method (or
equivalent) may be used to establish (a). Cast surfaces may be reworked to
rod length when replacing an adapter. depth of 0.020 inch (0.508 mm).
(a). Measure length and record position (b). Flat machined surfaces, except clevis
of rod end in adapter; then remove inner ears, may be reworked to depth
affected rod end. of 0.015 inch (0.381 mm). Clevis
inner ear surfaces may be reworked
(b). Comply with precaution above and to depth of 0.020 inch (0.508 mm).
drill out rivets securing adapter to
rod and aft rod end. (c). Machined holes may have 0.003 inch
(0.076 mm) removed from bore wall
(c). Install rod end in replacement in an area no greater than 15 percent
adapter and position at recorded of circumference and 50 percent of
measurement. depth.
(d). Fit adapter into rod and position to (d). All edges may have 0.030 inch (0.762
fit trammel point spacing; pick up mm) removed except around ma-
and drill through existing rivet holes chined holes, which are limited to
in rod and install rivets to secure 0.010 inch (0.254 mm) chamfer.
adapter to rod; at aft end, drill and
rivet rod end to adapter. (e). All rework must be smoothly blended
into adjacent surfaces and finish
(5). Replace unserviceable bellcrank and must be restored (Ref. preceding
support pivot bearings. Install bearing NOTE).
with grade A locking compound
(CM431). Make sure that bearing seats (7). Repair surface abrasion on Sta. 120
against bore shoulder. control rod by smoothing area with
grade 400 abrasive cloth (CM802) and
NOTE: restoring protective finish with primer
D Installation direction of Sta. 142 bell- (CM318). Replace rod if wear or depth
crank bearing may be from either side, of repair exceeds 0.004 inch (0.102
depending on location of bearing shoul- mm).
der. There must not be less than 0.010
inch (0.254 mm) protrusion of bearing in- (8). Replace tailboom control rod if hard
ner race beyond sides of bellcrank after anodic coating is worn through and
bearing is installed. aluminum base metal is visible.
D If contact is noted between Sta. 142 bell- (9). Replace split or torn boot. Remove Sta.
crank and mount bracket, rework bell- 120 control rod. Replace boot and
crank to clear bracket (Ref. Figure 801). reinstall Sta. 120 control rod.
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BELLCRANK AND SUPPORT

(2 PLS) (NOTE 1)
0.002 IN. NOTES

A S 2&3
(0.508 MM)
0.750 IN.
NOTES (19.05 MM)
0.090 IN. (2.286 MM) R 2&3 MIN.
369A795123
(TYP) BEARING
NOTES:
1. 0.010 MINIMUM CLEARANCE REQUIRED IN THIS AREA.
2. TREAT MACHINED AREA WITH CHROMIC ACID SOLUTION (CM207).
3. TOUCH UP COLOR 34151 GREEN (CM304).
G672003A
Figure 801. Rework of Sta. 142 Bellcrank Assembly

4. Station 78.50 Tail Rotor (TunnelRouted) temporarily reinstall washer and nut
Control Rod on bolt.
All tunnelrouted control rods are removed, (5). Slide pedal bracket and pedal arms off
inspected, repaired and installed in same end of torque tube.
manner. For initial length and rod end
angularity, Ref. Figure 402. For maintenance (6). Do not remove two teflonlined bush-
information, Ref. Sec. 671000. ings from right pedal arm, unless
replacement is required.
A. Tail Rotor Idler Bellcrank
(7). Do not remove two stop bolts, jam nuts
(Ref. Controls Support Bracket and Bellcrank, on stop bolts or bearings from pedal
Sec. 671000) bracket unless replacement is required.
5. Tail Rotor Pedal Disassembly (8). Slide torque tube bracket and control
rod fitting off torque tube.
(Ref. Figure 402)
6. Tail Rotor Pedal Repair
(1). Before disassembly of tail rotor pedal
installation, matchmark mating pedal (Ref. Figure 402)
arms, links and bellcranks with pedal
brackets to avoid intermixing compo- Consumable Materials
nents between locations at reassembly. (Ref. Section 910000)
Item Nomenclature
(2). Disconnect links from pedal arms and
bellcrank; remove links. CM425 Sealing compound
(3). Remove bellcrank from pedal bracket.
(4). Remove nut and washer of two bushing (1). Replace parts that are cracked or have
assemblies that secure left pedal arm elongated attachment holes. Do not
and control rod fitting to torque tube. attempt to straighten bent torque tube
Carefully remove bushing bolt and or pedal link.
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MAINTENANCE MANUAL
(2). Replace unserviceable pedal covers. mm). Torque nut to 50 80 inch

Apply sealing compound (CM425) to pounds (5.65 9.04 Nm) plus drag
approximately 30 percent of upper and torque. Do not allow bolt to turn.
lower edge surfaces that contact pedal.
Cure according to container instruc- (6). Check that each end of bushing assem-
tions. bly shank protrudes at least 0.002 inch
(0.051 mm). If not, loosen and repeat
(3). Replace complete pedal link if it is step (4). above.
cracked or contains unserviceable
bearings; bearings are not replaceable. (7). Check that slotted bushing is in place;
then attach bellcrank to pedal bracket
(4). Replace unserviceable bearings in with bolt, two washers, nut and cotter
mounting brackets or pedal link pin.
bellcrank. Install replacement with
grade A locking compound (CM431). (8). Check that slotted bushings are in
place; then fasten each link to bellcrank
Right pedal arm bushings are with bolt, two washers, nut and cotter
CAUTION glassfilled phenolic. Make cer- pin.
tain that bushing does not cock during re-
placement, and that it is fully seated in arm (9). Check that slotted bushings are in
bore. Keep tools from contact with bushing place; then fasten each link in pedal
liners to avoid fraying. arm lugs with bolt, two washers, nut
and cotter pin.
(5). Replace bearings in right pedal arm
when teflonreinforced liner is galled or (10). Ensure outboard pedals clear windows
frayed. Pull bushing to remove; press to by a minimum of 0.20 inch (0.508 mm)
install. with 20 pounds (88.96 N) of force
applied.
(6). Remove corrosion from pedal brackets
(Ref. Sec. 204000 and CSPA3, 8. Tail Rotor Bungee Spring Forward
Corrosion Control Manual). Attachment Relocation
(Ref. Figure 802) The information given in this
7. Tail Rotor Pedal Reassembly procedure is for the relocation of the tail rotor
(Ref. Figure 402) bungee spring forward attachment on 369D
helicopters, Serial No. 003D 0467D. This
(1). When reassembling components, check rework allows for the installation of washers,
for correct matchmark identification. for bungee adjustment, to adjust for minimum
pedal loads in cruise.
(2). If previously removed, thread jam nut
on each of two stop bolts and install two Consumable Materials
stop bolts into threaded inserts of pedal (Ref. Section 910000)
brackets. Item Nomenclature
(3). Slide torque tube bracket and control CM207 Chromic acid solution
rod fitting onto torque tube. CM318 Primer
(4). Locate pedal bracket and pedal arms
for correct position on torque tube; slide
bracket and arms onto torque tube. (1). Remove access cover between pilots
seats and/or passengers footwell on aft
(5). Fasten left pedal arm and control rod side of canted bulkhead.
fitting to torque tube with adjustable
bushing assemblies. Install bushing (2). Block left tail rotor control pedal at full
bolt so that shank at bolthead end forward position to relieve tension on
protrudes at least 0.002 inch (0.051 bungee.
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MAINTENANCE MANUAL
CL SHIP
OLD HOLE
3.25 IN. (8.255 CM)
NEW HOLE
3.37 IN. (8.5598 CM)
1.75 IN. (4.445 CM)
0.1900.194 IN. DIA. HOLE

(4.8264.9276 MM)
CC VIEW LOOKING AFT

C AN42BC10A EYEBOLT
AN9703 WASHER (8 REQUIRED)
STA MS210423 NUT
63.00 AN96010L WASHER
369A2541 BRACKET
CL SHIP
3.37 IN. B B
(8.5598 CM) 1.75
0.1900.194 IN. 369D27521 SPRING

DIAMETER THRU BRACKET
(4.8264.9276 MM)
C
BB VIEW LOOKING DOWN

VIEW LOOKING INBOARD LH SIDE
G762007A
Figure 802. Relocation of Tail Rotor Bungee Spring Forward Attachment
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672010 Revision 21
MAINTENANCE MANUAL
(3). Disconnect bungee spring from eyebolt end of 369D27521 bungee spring to
and remove and retain nut and washer eyebolt. Insert eyebolt in new hole in
attaching eyebolt to bracket at Sta. 63, 369A2541 bracket and secure with
discard eyebolt. washer and nut retained from prior
step. Torque nut to 20 25 inch
(4). Locate position and drill new hole using pounds (2.26 2.82 Nm).
No. 10 drill, deburr as required.
NOTE: If tail rotor pedal forces are not zero
(5). Seal old eyebolt hole with adhesive during level flight at 130 140 knots, tail ro-
(CM411). Allow to dry per manufactur- tor force adjustment may be accomplished
ers instructions. by removing a desired number of AN9703
washers.
(6). Treat edge of new hole with chromic
acid solution (CM207) and touch up (8). Remove block from left tail rotor control
with zinc chromate primer (CM318). pedal.
(7). Install eight AN9703 washers on one (9). Reinstall access cover between pilots
AN42BC10A eyebolt and hook forward seats and/or passengers footwell.
Page 806
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MAINTENANCE MANUAL
Section
672030
NOTARr
AntiTorque System
Flight Controls
(500/600N)
MAINTENANCE MANUAL
NOTAR ANTITORQUE SYSTEM FLIGHT CONTROLS

1. NOTAR AntiTorque System Control a stability augmentation system
Linkages Configuration and Description (S.A.S.).
(1). The helicopter may be equipped with 2. Stability Augmentation System

either of two basic configurations, Description and Operation
single lefthand command or right
hand command, (dual control are NOTE: Aircraft equipped with YSAS cannot be
optional). flown with any component of the system re-
moved.
NOTE: (1). The Yaw Stability Augmentation
D The 600N helicopter does not have a System provides increased directional
spring on the splitter assembly like the stability and allows for a lower pilot
500N helicopter. workload in the directional axis.
D Some 600N helicopters are not equipped (2). The YSAS adds an actuator that is
with a YSAS system. located inside the right side of the
D The 600N helicopter has a Sta. 95 bell- horizontal stabilizer and is mechanical-
crank instead of a Sta. 97.50 Bellcrank. ly bolted to the horizontal stabilizer on
the outboard side.
(2). The control linkages for the foot pedals (3). Two access panels on the horizontal
installation are identical to the basic stabilizer allows access to the actuator,
helicopter, with the exception of a pedal bellcranks, control rod and electrical
friction mechanism with a preset connectors.
friction tension. The pedal friction
mechanism (500N only) offers the pilot (4). A yaw rate gyro is located under the
an artificial feel or workload of a pilots seat structure on the foreword
conventional tail rotor system. bulkhead. Access to the gyro is through
the rear access panel (footwell) Sta.
(3). A splitter bungee spring (500N only) 78.50 canted bulked.
which is incorporated in the flight
control system at the mast base The yaw rate gyro provides short term
between the 97.50 bellcrank support rate signals to the computer, propor-
bracket and splitter pinion gear tional to the rate of angular displace-
dampens control feedback. ment about the axis perpendicular to
the gyros mounting surface damping in
(4). Fuselage controls linkages consist of the directional axis signal electronical-
Sta. 97.50 bellcrank and a support at ly.
the front of the main rotor mast base,
fwd control tube, splitter bungee spring, (5). A YSAS electronic control box (comput-
splitter assembly, intermediate control er) is installed below the rate gyro. It is
tube, Sta. 137.50 support bracket and a equipped with an internallymounted
bellcrank at the fan transmission lateral accelerometer.
support assembly, aft control tube and a The lateral accelerometer enhances
two piece cable assembly to the thrust- direction stability by feeding back to
er. the YSAS computer signals measured
during flight. The computer processes
(5). Empennage controls consist of a the signals received and sends them to
thruster installation, four piece cable the actuator.
and drum assembly, a control rod,
vertical stabilizer control tubes and (6). The 600N helicopters come equipped
bellcranks and, in the case of the 500N, with an indicator mounted in the
Page 1
672030 Revision 34
MAINTENANCE MANUAL
console to alert the pilot in case of a

YSAS failure.
3. 500NM7301 YSAS Fin Position Indicator
(U.K. Only)
(Ref. Table 1) The 500N helicopters sold in the
United Kingdom come equipped with an
indicating system to alert the pilot in case of a
YSAS failure. Because this is a very limited
option, the parts are not listed in CSPIPC4.
The following table is for ordering the major
components of this system.
Table 1. 500NM7301 YSAS Fin Position

Indicator Components
Edge light panel 369D2645427
Indicator 500N73053
Vne card set 500N653031
369D245069 Indicator
PFM Flight Manual Supplement CSP520N1C
369D2645417 Decal
Page 2
Revision 25 672030
MAINTENANCE MANUAL

1. AntiTorque Flight Controls 3. Forward Directional Control Tube
Replacement
NOTE:
(Ref. Figure 401)
D The NOTAR antitorque control system
must be rerigged after removal or re- A. Forward Directional Control Tube
placement of control rods, linkages and Removal
components or if helicopter operation re- (1). Remove fairings, access covers and
veals a rigging deficiency. doors necessary to facilitate mainte-
D Refer to adjustment and test control rig- nance (Ref. Sec. 533030, Upper Aft
ging, during flight control installation. Section Fuselage).
(2). Disconnect forward directional control
2. Upper Fuselage Sta. 97.50 (500N) or Sta. tube from Sta. 97.50 (Sta. 95) bellcrank.
95 (600N) Bellcrank and Support Bracket
Replacement (3). Disconnect forward directional control
tube from the lever assembly gear
(Ref. Figure 401) pinion rack Sta. 113.00 splitter and
remove control tube.
A. Sta. 97.50 (500N) or Sta. 95 (600N) B. Forward Directional Control Tube
Bellcrank and Support Bracket Removal Installation
(1). Disconnect antitorque control tube (1). Forward directional control rod initial
(Sta. 87.50) and Fwd directional control length is 15.42 inches (39.17 cm),
tube from Sta. 97.50 (Sta. 95) bellcrank. measured center of rod end to center of
rod end. Install forward directional
(2). Remove nuts, washers and bolts from control tube on pinion gear rack lever
main rotor mast base support bracket. assembly Sta. 113.00 splitter and on
Remove bellcrank and support bracket Sta. 97.50 (Sta. 95) bellcrank.
as an assembly. (2). Ensure slotted bushings are in place.
Split bushings must protrude 0.010
B. Sta. 97.50 (500N) or Sta. 95 (600N) 0.060 inch (0.254 1.524 mm) above
Bellcrank and Support Bracket surface of bellcranks.
Installation
(3). Install washers, bolts and nuts. install
(1). Position bellcrank and support bracket cotter pins and safety wire jamnuts as
on mast base structure,and install required.
three bolts, seven washers and three
(4). Install fairings and panels.
nuts. Most forward bolt requires extra
thick washer under head of bolt. Torque 4. Splitter Bungee Spring Replacement
bolt to 80 100 inchpounds (9.04 (500N)
(Ref. Figure 401)
(2). Ensure slotted bushings are in place
and connect antitorque control tube Special Tools
and fwd rod end of Fwd directional (Ref. Section 910000)
control tube to bellcrank and cotter pin. Item Nomenclature
Split bushings must protrude 0.010 ST601 Rigging pin
0.060 inch (0.254 1.524 mm) above ST602 Spring tension removal tool
surface of bellcrank.
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672030 Revision 18
MAINTENANCE MANUAL
A. Splitter Bungee Spring Removal (4). Remove nut, washer, link assy. and
spacer and disconnect intermediate
(1). Using two pieces of wood and Cclamp control tube from gear pinion stud.
or rope, secure pilots pedals in mid
position so they are aligned. (5). Remove four bolts and washers, and
remove splitter assembly.
(2). Insert rigging pin (ST601) into the
upper hole of bracket assembly and B. Station 113.00 Splitter Assembly and
through the the slot marked M in the Bellcrank Installation
gear pinion rack. (View B).
(1). Position splitter bracket on structure
Bungee spring is under ten- and install four bolts and washers.
WARNING sion, use care to prevent per-
(2). Position intermediate control tube on
sonal injuries or damage to aircraft.
gear pinion stud. Install link, spacer,
(3). Disconnect spring from links, either aft washer and nut; install cotter pin.
or fwd., using a spring expansion tool (3). During installation of walking lever
(ST602). and bracket, align the index marks
B. Splitter Bungee Spring Installation together and install pivot bolt, spacer,
washers and nut and torque to 50 60
(1). Insert rigging pin (ST601) into the inchpounds (5.65 6.78 Nm).
upper hole of bracket assembly and Ensure bushings and bearings are in
through the the slot marked M in the place; install cotter pin.
gear pinion rack Sta. 113.00 splitter.
(4). Install forward cable assembly rodend
(2). With a spring expansion tool (ST602), and fwd directional control tube rodend.
expand the spring the amount neces- Ensure bushings are in place. Torque
sary to secure the spring to the forward nuts and install cotter pin.
and aft links. (5). 500N Only: Install splitter bungee
(3). Remove rigging pin. spring.
6. Intermediate Control Tube Replacement

5. Upper Fuselage Station 113.00 Splitter
Assembly and Bellcrank Replacement (Ref. Figure 402)
(Ref. Figure 402) A. Intermediate Control Tube Removal
A. Station 113.00 Splitter Assembly and (1). 500N Only: Remove splitter bungee
Bellcrank Removal spring from Sta. 113.00 splitter assem-
bly pinion gear (Ref. Splitter Bungee
(1). 500N Only: Remove splitter bungee Spring Replacement (500N)).
spring from Sta. 113.00 splitter assem-
bly pinion gear (Ref. Splitter Bungee (2). Disconnect intermediate control tube
Spring Replacement (500N)). from gear pinion stud by removing nut,
washer, link and spacer.
(2). Disconnect forward cable assembly
rodend and rodend of forward direction- (3). Disconnect aft end of intermediate
al control tube from walking lever. control tube at Sta. 137.50 bellcrank by
depressing pin in head of bolt to release
NOTE: Note relationship of index marks on locking ball while removing nut. With
splitter assembly. pin still depressed, remove bolt.
(3). Align index marks on gear teeth. (4). Remove control tube boot tystrap, and
Remove walking lever from splitter move control tube carefully forward
bracket by removing nut, pivot bolt, through boot, support tube at plenum
washers and spacer. chamber inlet.
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MAINTENANCE MANUAL
AFT CONTROL ROD
SECTOR ASSEMBLY
TURNBUCKLE
IDLER PULLEY
DRUM ASSEMBLY MD500N

FWD TUBE
ASSEMBLY AFT CONTROL ROD
SECTOR ASSEMBLY
STA. 97.50 IDLER PULLEY

BELLCRANK
TURNBUCKLE
DRUM ASSEMBLY
MD500N
STA. 78.50 VIEW ROTATED 180 MD600N
CONTROL ROD
FWD TUBE ASSEMBLY DRUM AND SECTOR ASSEMBLY
FWD DIRECTIONAL
CONTROL TUBE
STA. 95
BELLCRANK
SPLITTER SPRING
STA. 78.50 (MD500N ONLY)
CONTROL ROD
MD600N
ROOFMOUNTED CONTROLS
RIGGING PIN
FWD CONTROL
CABLE
INTERMEDIATE SPLITTER ASSEMBLY

CONTROL TUBE G672013A
Figure 401. AntiTorque Control System
Page 403
672030 Revision 18
MAINTENANCE MANUAL
B. Intermediate Control Tube Installation 7. Station 137.50 Support Bracket and

Bellcrank Replacement
(1). Carefully feed intermediate control
tube through boot if installed and (Ref. Figure 402)
forward air inlet to bellcrank at Sta. A. Station 137.50 Support Bracket and
137.50. Bellcrank Removal
(2). Connect control tube and check that (1). Disconnect intermediate control tube
bushings are in place. from upper end of Sta. 137.50 bellcrank
by depressing pin in head of bolt to
(3). Install impedance bolt as follows: disengage and release locking ball and
removing nut. With pin still depressed,
NOTE: Install bolthead up, nut facing down. remove bolt.
(a). Depress pin in head of bolt to install (2). Disconnect link assembly at clevis,
bolt though clevis assembly. remove bolt in same manner as in
previous step.
NOTE: In the following step, pin is to remain (3). Remove four support bracket assembly
depressed while nut is torqued. bolts from fan transmission support.
(b). While pin is depressed, install nut (4). Bellcrank and bracket assembly may be
and torque to 40 50 inchpounds separated by removing bolt.
(4.52 5.65 Nm). B. Station 137.50 Support Bracket and
Bellcrank Installation
(c). Release pin and retorque nut to 75
90 inchpounds (8.47 10.17 Nm) NOTE: It is recommended to assemble link and
to ensure engagement of locking balls bracket assembly to bellcrank before install-
with nut. ing bracket assembly on fan transmission
support bracket.
NOTE: Pin must be in the released position
(flush with bolt head) and bolt must pro- (1). Reassemble bellcrank and bracket
trude past the nut for proper installation. assembly if necessary.
(2). Install impedance bolt as follows:
(d). Apply torque stripe.
(a). Depress pin in head of bolt to install
(4). Install alternate NAS620411D bolt bolt through bracket and bellcrank.
and MS178264 nut as follows: NOTE: In the following step, pin is to remain
depressed while nut is torqued.
(a). Install bolt, with one AN960KD416L
washer through clevis assembly. (b). Install nut and torque to 100 120
(b). Install AN960KD416L washer and
nut and torque to 20 40 inch (c). Release pin and torque nut to 200
pounds (2.26 4.52 Nm); install 225 inchpounds (22.60 25.42
MS24665134 cotter pin. Nm) to insure engagement of locking
ball with nut.
(5). Position rubber boot in place. Secure NOTE: Pin must be in the released position
boot at support tube with nylon strap, (flush with bolt head) and bolt must pro-
then clamp directional control pedals in trude past the nut for proper installation.
neutral, set free length of bellows
portion of boot at approximately 5.5 (d). Apply torque stripe.
inches (13.97 cm) and secure end to (3). Install alternate NAS620629D bolt
control tube with nylon strap. and MS178266 nut as follows:
(6). 500N Only: Install splitter bungee (a). Install bolt, with one AN960KD616L
spring. washer through clevis assembly.
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Revision 33 672030
MAINTENANCE MANUAL
(b). Install AN960KD616L washer and NOTE: The Fan Pitch Control Tube can be re-
nut and torque to 95 110 inch moved in either one of the following steps.
pounds (10.73 12.43 Nm); install The fan assembly pitch bearing slider, pitch
MS24665285 cotter pin. bearing retainer, pitch plate bearings and
bearing retainer nut with aft control tube
(4). Install lower bolt at link assembly and can be removed as a unit or individually.
bellcrank clevis, and upper bolt inter- Use extreme care do not damage parts.
mediate control tube Sta. 137.50
bellcrank bolts as follows: (1) Remove locking wire and remove nut and
lock washer from fan pitch control tube.
NOTE: Install bolthead up, nut facing down. Remove locking wire and remove three
bolts and washers from pitch bearing re-
(a). Depress pin in head of bolt to install tainer housing. Pitch bearing slider, pitch
bolt through clevis end of bellcrank. plate bearings and, bearing retainer nut
with aft control tube can be removed as a
NOTE: In the following step, pin is to remain unit.
depressed while nut is torqued.
(2) Remove locking wire and remove six pitch
(b). While pin is depressed, install nut bearing housing assembly bolts. Remove
and torque to 40 50 inchpounds pitch bearing retainer housing assembly
(4.52 5.65 Nm). as a unit.
(c). Release pin and retorque nut to 75 B. Fan Pitch Control Tube Installation
to ensure engagement of locking balls NOTE:
with nut. D Refer to Fan Pitch Control Rigging during
installation.
NOTE: Pin must be in the released position
(flush with bolt head) and bolt must pro- D Before installing fan pitch control tube,
trude past the nut for proper installation. perform Fan Pitch Control Tube Inspec-
tion.
(d). Apply torque stripe.
(1). Install the aft control tube.
(5). Install alternate NAS620411D bolt
and MS178264 nut as follows: (2). Install convoluted boot on fan gearbox
or clevis.
washer through clevis assembly. NOTE: In the following step, clevis should be
bottomed into control tube, approximately
(b). Install AN960KD416L washer and one thread showing after engagement.
pounds (2.26 4.52 Nm); install (3). Install clevis assembly on aft control
MS24665134 cotter pin. tube. Ensure that clevis has full thread
engagement on control tube.
(6). Install four support bracket assembly
bolts and washers to fan transmission (4). Ensure locking washer tang tip is in
support. Torque bolts to 70 90 slot. Tighten jam nut against locking
inchpounds (7.91 10.17 Nm); washer and safety wire from lock to
safety wire bolts. nut. Ensure safety wire pigtail is on the
nut.
8. Fan Pitch Control Tube Replacement
(5). Install floating bushing in clevis.
A. Fan Pitch Control Tube Removal
(6). Install bolt, bolthead on floating
(1). Remove tail boom fairing and tail boom. bushing side of clevis, through clevis
and link assembly as follows:
(2). Remove bolt and clevis assembly at Sta.
137.50 bellcrank. Remove convoluted (a). Depress pin in head of bolt to install
boot from fan gearbox. bolt through clevis end of bellcrank.
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MAINTENANCE MANUAL
NOTE: In the following step, pin is to remain of three threads protruding beyond the
depressed while nut is torqued. face of the jam nut.
(b). While pin is depressed, install nut (13). Install two lockwires on jamnut and
and torque to 40 50 inchpounds lockwasher.
(4.52 5.65 Nm).
NOTE: After safety wiring nut and bolts, rotate
(c). Release pin and retorque nut to 75 fan and ensure that safety wires do not have
90 inchpounds (8.47 10.17 Nm) interference with each other on rotation.
to ensure engagement of locking balls
with nut. (14). Install tail boom (Ref. Sec. 534030).
NOTE: Pin must be in the released position 9. Forward Cable Assembly Replacement
(flush with bolt head) and bolt must pro-
trude past the nut for proper installation. (Ref. Figure 402)
(d). Apply torque stripe. A. Forward Cable Assembly Removal
(7). Install alternate NAS620411D bolt To prevent damage to the engine

CAUTION install F.O.D. cover over engine
and MS178264 nut as follows:
air inlet.
washer through clevis assembly. (1). Remove fairings, access doors and
panels necessary to facilitate mainte-
(b). Install AN960KD416L washer and nance (Ref. Sec. 533030).
pounds (2.26 4.52 Nm); install (2). Remove tailboom fairing.
MS24665134 cotter pin.
(3). Disconnect the aft end of the anti
NOTE: Before installing fan pitch slider, per- torque control cable by turning outside
form Fan Pitch Slider Inspection. collar sleeve counterclockwise and
back to expose the inner cable.
(8). Install pitch bearing slider and bearing
retainer per rigging instructions. (4). Apply sufficient right pedal to expose
inner cables.
(9). Install pitch bearing and pitch bearing
retainer housing using three bolts and (5). Without bending cable, slide male
washers. Torque bolts to 70 80 connector out of female connector.
inchpounds (7.91 9.04 Nm); safety
wire bolts. (6). Disconnect cable assembly forward
rodend from Sta. 113.00 splitter
(10). Install lockwasher so that the face of assembly outboard bellcrank clevis.
the tang aligns with the tube assembly
keyway, and the lockwasher aligns with (7). Loosen jam nut at rodend and remove
one of the six slots in the face of the rodend from cable; remove jam nut.
bearing retainer. (8). Remove safety wire, jam nuts and
(11). Install jamnut on aft control tube. washers from cable assembly support
bracket, remove by pulling or sliding
(12). Torque nut to 95 110 inchpounds cable assy. thru conduit and support
(10.73 12.43 Nm) leaving a minimum bracket.
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MAINTENANCE MANUAL
CABLE ASSY
INTERMEDIATE
SPLITTER ASSY TUBE ASSY
FORWARD
TUBE ASSY
STA. 137.50
BRACKET
STA. 137.50
BELLCRANK
NOTE 2
NOTE 1
FAN PITCH
CONTROL TUBE
FLOATING
BUSHING
NOTES: ROTATED
1. CLEVIS FULLY ENGAGED INTO FAN LINK ASSY
PITCH CONTROL TUBE.
2. SAFETY FROM LOCKING WASHER TO NUT. G6720081E
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 1 of 2)
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MAINTENANCE MANUAL
CLAMP
STA. 304.00
STA. 123.30 MD500N
FITTING
SUPPORT BRACKETS
STA. 131.50 AND 151.00
SUPPORT BRACKET AND CABLE

ASSY. TAILBOOM STA. 264.00 STA. 303.30
MD600N
RIGHT CONTROL ROD
BELLCRANK
CENTER
BELLCRANK LEFT CONTROL ROD
SHAFT
MD600N
INNER MALE
CONNECTOR TORQUE TUBE
INNER FEMALE
HOUSING
CONNECTOR
FORWARDTOCENTER
CABLE CONNECTION MD500N
VERTICAL STABILIZER
CONTROL RODS
G6720082D
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 2 of 2)
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Revision 25 672030
MAINTENANCE MANUAL
B. Forward Cable Assembly Installation (b). Without bending cable, insert inner
male connector into inner female
connector and ensure they are
Consumable Materials properly engaged together.
Item Nomenclature (c). Slide outside cable collar over
CM702 Lockwire CRES forward cable to engage locking
device and turn clockwise until fully
locked.
Before installation of cable, in-
CAUTION spect cable (Ref. Forward and (12). Verify rigging of cable assembly from
Center Cable Assembly Inspection). Sta. 113.00 splitter assembly (Ref.
Adjustment/Test).
(1). Install one jam nut and washer on cable
and insert cable assembly through (13). Install fairings, access doors and panels
support bracket and conduit. removed for installation.
(2). Install washer and one jam nut on cable 10. Center Cable Assembly Replacement
forward side of support bracket.
(Ref. Figure 402)
(3). Ensure that the threaded portion is
centered in the support bracket. A. Center Cable Assembly Removal
NOTE: When tightening cable jamnuts, ensure (1). Remove rotating thruster cone (Ref.
smooth action of cable and alignment of Sec. 534030).
cable hex end into cable socket. (2). Remove stationary thruster cone (Ref.
Sec. 534030).
(4). Ensure cable hex end and cable socket
are aligned to ensure smooth action. (3). Remove cotter pin, nut, washers and
bolt from clevis end of control rod
(5). Slide cable in and out to ensure there is
double rodend.
no binding and tighten jamnuts.
(4). Disconnect cable assembly double rod
(6). Slide cable in and out again to ensure end bearing from center tailboom
there is no binding. If cable slides bellcrank.
smoothly, safety jamnuts (CM702).
(5). Remove double rod end from cable
(7). Install rodend bearing with locking assembly.
device and jamnut.
(6). Remove tailboom fairing.
(8). Ensure that threads protrude past
witness hole. Tighten jamnut and (7). Disconnect the forward end of the
safety wire nuts. antitorque control cable by turning
forward cable outside collar sleeve
(9). Connect cable assembly forward rodend counterclockwise and back to expose
to Sta. 113.00 splitter assembly out- the inner cable.
board bellcrank clevis.
(8). Apply sufficient right pedal to expose
(10). Torque nut and install cotter pin. inner cables.
(11). Reconnect forward and center control (9). Without bending cable, slide male
cable couplings. connector out of female connector.
Failure to properly connect (10). Disconnect cable assembly forward
WARNING thruster cables could result rodend from Sta. 113.00 splitter
in uncoupling during flight and loss of assembly outboard bellcrank clevis.
antitorque authority.
(11). Remove safety wire and aft jamnut
(a). Apply sufficient right pedal to expose from cable assembly support bracket.
inner cable female connector. Cable assembly can be removed by
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672030 Revision 33
MAINTENANCE MANUAL
sliding or pulling cable assembly Failure to properly connect

through support bracket and conduit WARNING thruster cables could result
and through grommet. in uncoupling during flight and loss of
antitorque authority.
B. Center Cable Assembly Installation
(a). Apply sufficient right pedal to expose
inner cable female connector.
Before installation of cable, in-
CAUTION spect cable (Ref. Forward and (b). Without bending cable, insert inner
Center Cable Assembly Inspection). male connector into inner female
connector and ensure they are
(1). Install one jam nut and washer on cable properly engaged together.
and route cable assembly thru conduit
of tailboom and thru support bracket. (c). Slide outside cable collar over
forward cable to engage locking
device and turn clockwise until fully
(2). Install washer and jamnut on cable aft
locked.
side of support bracket.
(11). Verify rigging of cable assembly from
(3). Ensure that the threaded portion is Sta. 113.00 splitter assembly to vertical
centered in the support bracket. stabilizers is correct.
NOTE: When tightening cable jamnuts, ensure (12). Install stationary thruster cone.
smooth action of cable and alignment of (13). Install rotating thruster cone.
cable hex end into cable socket.
11. Aft Control Rod Assembly Replacement
(4). Ensure cable hex end and cable socket (Ref. Figure 402)
are aligned to ensure smooth action.
A. Aft Control Rod Assembly Removal
(5). Slide cable in and out to ensure there is
no binding and tighten jamnuts. (1). Remove thruster cone (Ref. Sec.
534030).
(6). Slide cable in and out again to ensure (2). Remove stationary thruster cone (Ref.
there is no binding. If cable slides Sec. 534030).
smoothly, safety jamnuts (CM702).
(3). Remove cotter pin, nut and washer
(7). Install double rodend bearing with from sector input shaft.
locking device and jamnut. (4). Remove pan cover.
(8). Ensure that threads protrude past (5). Remove cotter pin, nut, washers and
witness hole. Tighten jamnut and bolt from clevis end of control rod at
safety wire nuts. double rodend bearing of tailboom
center cable assembly.
NOTE: The split bushing is installed at the top (6). Remove and discard lockwire and then
of bellcrank. A minimum of 0.010 inch remove control rod bolt from sector
(0.254 mm) and a maximum of 0.060 inch assembly.
(1.524 mm) split bushing protrusion re-
quired above surface. (7). Remove control rod.
B. Aft Control Rod Assembly Installation
(9). Install double rodend bearing and
forward bearing to bellcrank with bolt,
washers and nut. Tighten nut and Consumable Materials
install cotter pin. (Ref. Section 910000)
Item Nomenclature
(10). Reconnect forward and center control CM702 Lockwire CRES
cable couplings.
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Revision 33 672030
MAINTENANCE MANUAL
NOTE: Split bushing is installed at the top, (6). Remove control rod bolt from sector
shoulder bushing is installed at bottom. A assembly and lift sector assembly from
minimum of 0.010 inch (0.254 mm) and shaft.
maximum of 0.060 inch (1.524 mm) split
bushing protrusion required above surface. (7). Remove clevis pins from sector assem-
bly and remove cables.
(1). Connect thruster control rod clevis end
to double rod end aft bearing of center B. Sector Assembly and Control Cable
cable assembly. Installation
(2). Install washer and bushing on bolt and

then insert through rod end into sector
assembly. Item Nomenclature
(3). Torque bolt to 30 40 inchpounds CM702 Lockwire CRES
(3.39 4.52 Nm) and install safety wire
(CM702). (1). Position the cable assembly around
thruster sector bellcrank, install cable
(4). Install bushings, bolt, washer and nut;
clevis pins and cotter pins.
(3.39 4.52 Nm) and install cotter pin. (2). Install sector bellcrank on input shaft.
(5). Install pan cover. (3). Connect sector assembly aft control rod
to clevis.
(6). Install washer and nut on sector input
shaft; torque nut to 95 110 inch (a). Install washer and bushing on bolt
pounds (10.73 12.43 Nm) and install and then insert through rod end into
cotter pin. sector assembly.
(7). Install stationary thruster cone. (b). Torque bolt to 30 40 inchpounds
(3.39 4.52 Nm) and install safety
(8). Install rotating thruster cone. wire (CM702).
12. Sector Assembly and Control Cable (4). Install bushing, washer on sector input
Replacement shaft.
(Ref. Figure 401) (5). Install pan cover.
A. Sector Assembly and Control Cable (6). Install washer and nut on sector input
Removal shaft; torque nut to 95 110 inch
pounds (10.73 12.43 Nm) and install
(1). Remove rotating thruster cone (Ref. cotter pin.
Sec. 534030).
(7). Install rotating thruster cone.
NOTE: Removed safety clips from turnbuckles (8). Perform a rigging check.
are not to be reused.
(2). Disconnect cables from turnbuckles in 13. Drum Assembly and Idler Pulley
access hole provided (top of stationary Replacement
cone). (Ref. Figure 401)
(3). Remove cotter pin, nut and washers A. Drum Assembly and Idler Pulley Removal
from sector input shaft.
(1). Remove rotating thruster cone (Ref.
(4). Remove pan cover. Sec. 534030).
(5). Remove washer and bushing under pan NOTE: Removed safety clips from turnbuckles
cover from sector bellcrank input shaft. are not to be reused.
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MAINTENANCE MANUAL
(2). Disconnect cables from turnbuckles in (2). Install drum assembly on shaft and
access hole provided (top of stationary install guard pins.
cone).
(3). Install HS306233H flat washer
(3). Remove cotter pin, nut and two wash- against the bearing.
ers, remove drum assembly from shaft. (4). Install washer and nut; torque nut to
160 190 inchpounds (18.08 21.47
(4). Remove guard pins to remove cable Nm) and install cotter pin.
assemblies.
(5). Install turnbuckles and cables.
B. Drum Assembly and Idler Pulley
Installation (500N) (6). Perform a rigging check.
NOTE: The long cable is 23.07 inches (58.60
cm) and is installed on the aft cable guide of 14. AntiTorque Pedal Friction Replacement
the drum, or right side, up and around the (Ref. Figure 403)
right idler pulley. The short cable is 22.82
inches (57.96 cm) long and is installed on A. AntiTorque Pedal Friction Removal
the fwd cable guide of the drum, or left side, (1). Remove bolt, washer and bushing from
up and round the left idler pulley. console support bracket.
(1). Install cables on drum assembly. (2). Remove nut and washers, remove
spring, retainer, spring and friction
(2). Install drum assembly on shaft and disc, and link.
install guard pins.
(3). Remove brace and clamp arm assembly
(3). Install HS306233H flat washer from antitorque tube assembly.
against the bearing. B. AntiTorque Pedal Friction Installation
(4). Install washer and nut; torque nut to (1). Using two pieces of wood and Cclamp
160 190 inchpounds (18.08 21.47 or rope, secure pilots pedals in mid
Nm) and install cotter pin. position so they are aligned within 0.50
inch (1.27 cm) of each other.
(5). Install turnbuckles and cables.
(2). Install washer, bolt, bushing, and link
(6). Perform a rigging check. assembly to bracket assembly on
instrument console.
(3). Install brace and clamp arm assembly
C. Drum Assembly and Idler Pulley to antitorque tube assembly.
Installation (600N)
(4). Install friction disc, link, retainer and
NOTE: The long cable is 23.76 inches (60.35 spring, install washer (shim washers if
cm) long and is installed on the aft cable required) and nut.
guide of the drum, or right side, over and (5). Torque brace and arm assembly bolts
around the left idler pulley. The short cable 30 35 inchpounds (3.39 3.95
is 23.51 inches (59.72 cm) long and is in- Nm). Torque nut against washer to
stalled on the fwd cable guide of the drum, obtain a pedal friction of 5 8 pounds
or left side, over and round the right idler (2.27 3.63 kg).
pulley.
15. AntiTorque Pedal Assembly
(1). Install cables on drum assembly as Replacement
follows:
(Ref. Figure 403)
(a). Install left cable on forward groove of A. AntiTorque Pedal Assembly Removal
drum and cross over to right pulley.
(1). Pull two hinge pins from pilots com-
(b). Install right cable on aft groove of partment floor access door hinges and
drum and cross over to left pulley. remove door.
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Revision 33 672030
MAINTENANCE MANUAL
STA. 97.50 BELLCRANK
STA. 97.50
(TUNNELROUTED)
CONTROL ROD
CONTROLS SUPPORT
BRACKET
INITIAL CONTROL ROD LENGTH ANTITORQUE PEDAL

FRICTION
BEFORE RIG
CONTROL DIMENSION L SPRING FITTING
ROD INCHES (CM) AFT EYEBOLT TAIL ROTOR IDLER
TUNNELROUTED 57.95 (147.193) STA. 63.00 BUNGEE BELLCRANK
FLOORROUTED 30.06 (76.3524) SPRING NOTE 2
FORWARD EYEBOLT
RIVET
NOTE 1 FLOORROUTED
CONTROL ROD
L
MAXIMUM ALLOWABLE LOOSENESS NOTE 2
0.040 IN. (1.016 MM) NOTE 3
TORQUE TUBE BUSHING ASSY
(NOTE 4)
* TORQUE TUBE BRACKET NOTE 1 NOTE 3
(NOTE 5)
CONTROL ROD FITTING
PIN NOTE 1
WASHER
NOTE 4
BEARING NOTE 1
* LEFT PEDAL
STOP BOLT BEARING
* RIGHT PEDAL
JAMNUT
NOTE 2
NOTE 3
NOTE 1
* PEDAL ARM
NOTE 1 * PEDAL BRACKET
BUSHING
* PEDAL ARM
(TEFLONLINED) NOTE 4
NOTE 2
BUSHING
(TEFLONLINED) NOTES:
BUSHING ASSY 1. SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416
(NOTE 4) LINK AND/OR 416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN
NOTE 2 0.010 IN. (0.254 MM).
2. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN.
NOTE 2 (0.254 MM) TO A MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE
BEARING BELLCRANK SURFACE OF PART AFTER NUT IS TIGHTENED.
3. DIRECTION OF BOLTS IS OPTIONAL.
4. ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF
0.002 IN. (0.051 MM) AT EACH END.
5. INSTALLED WITH BEARING RECESS FACING FITTING.
6. ASTERISK (*) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR
ALUMINUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
CONTROL REF. SEC. 204000. G6720013
Figure 403. Pedal Installation (Sheet 1 of 2)
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672030 Revision 25
MAINTENANCE MANUAL
RIGHT POSITION
ANTITORQUE PEDALS STOP BOLT
(2 EACH)
NOTE 1
NOTE 2
JAMNUT
ADJUSTABLE BUSHING
ASSEMBLY (NOTE 4) NOTE 3
TORQUE TUBE
SLOTTED BUSHING
(TYPICAL) (NOTE 2)
SLEEVE TORQUE TUBE
ADJUSTABLE BUSHING
ASSEMBLY (NOTE 4)
G6720014
Figure 403. Pedal Installation (Sheet 2 of 2)

(2). Remove access panel from each side of simplify torque tube alignment during
instruction panel lower support struc- reinstallation.
ture.
(8). Remove four nuts, eight washers, any
(3). Remove battery (Ref. Sec. 960000). shims washers and four bolts that
secure pedal bracket to bulkhead.
(4). Remove pins securing pedals to pedal (9). Remove control pedal installation. Keep
arms and remove pedals. shim washer selection with bracket for
reinstallation.
(5). Remove pedal friction mechanism.
B. AntiTorque Pedal Assembly Installation
(6). Remove cotter pin, nut, two washers (1). Install pedal bracket with four bolts,
and bolt that connect floorrouted eight washers and four nuts.
control rod to torque tube fitting.
(2). Add shim washers as required at pedal
(7). Remove two nuts, four washers, any bracket attachment points to keep
shim washers and two bolts that secure centerline alignment of pedal bracket
torque tube bracket to bulkhead. Keep bearings within 0.010 inch. Correct
shim washer selection with bracket to alignment is indicated by free rotation-
Page 414
Revision 30 672030
MAINTENANCE MANUAL
al movement of torque tube after nuts NOTE: Observed and note position of vertical
are torqued with no evidence of binding. stabilizer bellcrank for reinstallation pur-
poses.
(3). Position torque tube bracket over
mating holes in bulkhead and check (6). Remove vertical stabilizer torque tube
alignment with bulkhead. (Ref. Sec. 535030, Vertical Stabilizer
Torque Tube and/or Bushing Replace-
(4). Add shim washers as required at ment).
bracket attachment points to maintain (7). Disconnect electrical connector from
bearing alignment established in step actuator.
(2). above. Install two bolts, four
washers and two nuts. (8). Disconnect S.A.S. actuator from control
rod.
(5). Check that slotted bushing is in place,
install floorrouted control rod in (9). Remove bolts from actuator support
torque tube fitting and install bolt, two bracket and carefully slide actuator out
washers and nut; install cotter pin. A of access hole.
minimum of 0.010 inch (0.254 mm) and B. S.A.S. Actuator Installation
a maximum of 0.060 inch (1.524 mm)
split bushing protrusion required above NOTE: Whenever S.A.S. actuator or control
surface. tube is replaced, S.A.S. rigging must be per-
formed.
(6). Install antitoque pedal friction
mechanism. (1). Slide actuator through access panel and
attach actuator to support bracket.
(7). Check rigging of pedal assembly (2). Install vertical stabilizer torque tube
controls and pedaltocanopy clear- (Ref. Sec. 535030, Vertical Stabilizer
ance. Pedals should clear windows by a Torque Tube Replacement).
minimum of 0.020 inch (0.508 mm) with
20 pounds (9.0718 Kg) of force applied. (3). Connect actuator control tube to
vertical stabilizer torque tube bell-
16. Stability Augmentation System (S.A.S.) crank. Torque nut to 30 40 inch
Actuator Replacement pounds (3.39 4.52 Nm) and install
cotter pin.
(Ref. Figure 505)
NOTE: Care should be observed to position ver-
A. S.A.S. Actuator Removal tical stabilizer bellcrank in the same posi-
tion as removed.
(1). Disconnect electrical power from (4). Reinstall upper and lower R/H vertical
aircraft. Ensure that battery power is stabilizers (Ref. Sec. 535030, Vertical
disconnect. Stabilizer Replacement).
(2). Remove horizontal stabilizer center (5). Reconnect electrical connector to
access panels and R/H end cap access actuator.
cover.
(6). Perform S.A.S. actuator rigging check
(3). Remove upper and lower R/H vertical (Ref. Stability Augmentation System
stabilizers (Ref. Sec. 535030, Vertical Rigging Instructions).
Stabilizer Replacement). (7). Install access panels.
(4). Disconnect actuator control tube from 17. S.A.S. Rate Gyro and Electronic Control
vertical stabilizer torque tube bell- Box (Computer) Replacement
crank.
Access to the rate gyro and electronic control
(5). Remove R/H vertical stabilizer torque box (computer) is through the passenger
tube bellcrank. compartment footwell access panels.
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672030 Revision 30
MAINTENANCE MANUAL
The units are mounted on a rack under the (2). Disconnect and remove electrical plug.
pilots seat structure against the seat structure
forward panel. (3). Remove mounting hardware.
The 500N has the components mounted (4). Carefully remove component from rack.
approximately 12 inches (30.48 cm) to the B. S.A.S. Rate Gyro and Electronic Control
right of centerline. Box (Computer) Installation
The 600N has the components mounted (1). Install component on rack.
approximately 12 inches (30.48 cm) to the left
of centerline. (2). Reinstall mounting hardware. Torque
screws to 12 15 inchpounds (1.36
A. S.A.S. Rate Gyro and Electronic Control 1.69 Nm) plus drag torque.
Box (Computer) Removal
(3). Connect electrical plug.
(1). Remove appropriate passenger
compartment footwell fairing (Ref. Sec. (4). Reinstall passenger compartment
525000). footwell fairing (Ref. Sec. 525000).
Page 416
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MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Directional Controls Rigging (3). Assemble the pitch plate control
bearing into slider and attach the
NOTE: bearing retainer plate using three bolts
and three washers.
D On the 500N, directional control rigging
is to be accomplished with the (Sta.
113.00) spring on the splitter assembly (4). Torque bolts to 70 80 inchpounds
disconnected. (7.91 9.04 Nm) and safety (CM702).
D The NOTAR control system must be re NOTE: Every 60 turn on bearing retainer is
rigged after replacement of control rods, equivalent to 0.6 degree change in fan pitch
linkages, and components or if helicopter angle.
operation reveals a rigging deficiency.
(5). Using the TICK marks on the fan blade
2. Fan Pitch Control Rigging assembly and on hub housing to
determine blade pitch angle, adjust
(Ref. Figure 501) bearing retainer to obtain a fan blade
pitch angle of 26 1 (View D).
NOTE:
Item Nomenclature D The aft control tube keyway should be in-
CM702 Lockwire CRES stalled at the 12 Oclock position for ease
of installation.
Special Tools D Ensure that one of the six slots in the face
(Ref. Section 910000) of the bearing retainer aligns with fan
Item Nomenclature pitchaft control tube key way (View C).
ST601 Rigging pin
(6). Install lockwasher so that the face of
the lockwasher aligns with one of six
NOTE: Fan Pitch Control Rigging shall be ac- slots of the bearing retainer.
complished with the tailboom and engine air
inlet fairings removed. (7). Install jam nut, torque nut to 95 110
inchpounds (10.73 12.43 Nm)
(1). Position Sta. 113.00 splitter assembly leaving a minimum of three threads
pinion gear so the rigging slot aligns protruding beyond the face of the jam
with lower rigging hole in the bracket nut.
assembly; Insert the rigging pin
(ST601) (View A). (8). Check tick marks on fan blade assem-
bly and hub housing, ensure that fan
(2). Adjust the bearing retainer so the pitch angle is 26 1. If blade pitch is 26
flange of bearing retainer is screwed in 1, proceed to step (9). If not, remove
on the tube assembly until it just jamnut and lockwasher and return to
touches the shoulder of the fan pitch steps (5).
aft control tube (View B).
(9). Safety wire (CM702) nut and lockwash-
NOTE: A gap of 0.0150.025 inch (0.3810.635 er (2 places required).
mm) between pitch bearing housing and
bearing retainer plate must exist to ensure (10). Rotate fan to ensure the safety wire
proper clampup. does not interfere.
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MAINTENANCE MANUAL
UPPER RIGGING
HOLE
FWD CONTROL
CABLE
SEVENTEEN TO SEVENTYSEVEN BRACKET

DEGREES AT 5 INCREMENTS ASSY
PINION GEAR
LOWER RIGGING
HOLE 500N9901
TICK MARKS 26 1 FAN C/L RIGGING TOOL
FAN HUB ASSY
77 17 SPLITTER ASSEMBLY
RIGGING LOCATION
FAN BLADE ASSY

BEARING RETAINER
TICK MARK LOCATION ASSEMBLY
ON FAN ASSEMBLY PITCH PLATE
CONTROL BEARING
ONE OF BEARING
SIX SLOTS RETAINER
FAN PITCH
CONTROL TUBE SLIDER
FAN PITCH CONTROL BEARING RETAINER

TUBE ASSY
KEYWAY TUBE LOCATION
BEARING RETAINER SLOT

AND KEYWAY ALIGNMENT
G672010
Figure 501. Fan Pitch Control Rigging
Page 502
Revision 18 672030
MAINTENANCE MANUAL
NOTE: they are aligned (View A). Maximum

D If the required adjustment of bearing re- misalignment between pedals shall be
tainer, lockwasher and jamnut cannot be 0.50 inch (1.27 mm).
achieved, adjust the intermediate control
NOTE: Do not adjust the control rod beyond the
tube to meet requirements of specifica-
witness hole. Do not tighten the locking
tions in steps (5). thru (10).
jamnut until after final adjustment.
D Do not adjust the control rodend beyond
the witness hole. Do not tighten jam nut (3). Antitorque idler bellcrank position to
until after final adjustment. be checked as follows:
(11). Remove rigging pin. (a). Position pilots foot pedals in neutral
and floorrouted control rod length
(12). Fan Pitch Control Rigging shall (initial control rod length is 30.06
produce the following results: inches (76.35 cm) before rigging).
(a). 500N:
(b). Adjust floorrouted control rod so
1). Full left pedal, 69 73 degrees. that centerline of bellcrank arm is
90 2 degrees to Sta. 78.50 canted
2). Full right pedal, 50 54 degrees. bulkhead (View B).
(b). 600N; (c). Sta. 97.50 bellcrank: Adjust the
1). Full left pedal, 71 75 degrees. tunnelrouted control rod so the
centerline of the tunnelrouted
2). Full right pedal, 52 56 degrees. control rod attach bolt in the transfer
bellcrank is 4.21 4.39 inches (10.69
NOTE: On the 600N helicopter, the pedal po- 11.15 cm) above mast base struc-
tentiometer rigging must be checked any ture (View C).
time the antitorque system has been ad-
justed. (4). Check witness holes for proper thread
engagement.
3. Pilot Pedal Rigging
(5). Tighten jamnuts and safetywire
(Ref. Figure 502) (CM702) as required.
Consumable Materials (6). Adjust rodends on the forward control

(Ref. Section 910000) tube so the rigging pin can be inserted
Item Nomenclature into the bracket assembly upper hole
CM702 Lockwire CRES
and through the slot marked M" in the
gear pinion rack Sta. 113.00 splitter
assembly (View D).
NOTE: Directional control rigging shall be ac-
complished with the (Sta.113) splitter (7). Remove rigging pin and remove
spring assembly disconnected (500N) and clamping device from foot pedal arms.
the fan pitch control rigging complete.
Use care when actuating pedals
CAUTION to avoid damaging tool or wind-
(1). Remove lefthand air inlet fairing to
facilitate pedal rigging (Ref. Sec. shield.
533030).
(8). Loosen jamnuts on pedal stopbolts
Remove pilots pedals and copi- (View A).
CAUTION lots (if installed) to prevent pos-
sible contact with lower windshield during (9). Screw in pedal stopbolts approximate-
rigging sequence. ly onehalf inch (12.7 mm).
(2). Using two pieces of wood and Cclamp (10). Adjust lefthand stopbolt in the pilots
or rope, secure pilots foot pedal arms so pedal support.
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MAINTENANCE MANUAL
MID PEDAL FWD CONTROL

RIGGING HOLE TUBE
FWD. CABLE
ASSEMBLY
FULL RIGH
RIGGING H
FULL LEFT PEDAL

RIGGING HOLE
RIGGING PIN
LOWER
STA 97.50 RIGGING HOLE
BELLCRANK
FULL LEFT PEDAL AND FULL RIGHT PEDAL

MIDTRAVEL RIGGING LOCATIONS
STA 113.00 SPLITTER ASSEMBLY
MAST BASE STA 78.50 (TUNNEL

4.30 ROUTED CONTROL ROD)
+0.090

STA 78.50 (TUNNEL

ROUTED CONTROL ROD)
CONTROLS SUPPORT
BRACKET
0.50 INCH MAXIMUM
MISALIGNMENT
BETWEEN PEDALS
CLAMPING BLOCKS
90+ 2 STA 78.50

CANTED BULKHEAD
RIGHT STOP BOLT
JAM NUT ANTI TORQUE

IDLER BELLCRANK
LEFT STOP BOLT
JAM NUT
FLOOR MOUNTED
CONTROL ROD
PEDAL ARM ALIGNMENT AND
STOP BOLT ADJUSTMENT
G672011
Figure 502. Pilot Pedal Rigging
Page 504
Revision 18 672030
MAINTENANCE MANUAL
(11). Apply full left pedal until the rigging 5. Thruster Control Rigging (500N)
pin can be inserted through the bracket
assembly upper hole and into the slot (Ref. Figure 503)
marked L in the gear pinion rack Sta.
113.00 splitter assembly (View D). Consumable Materials
(12). Adjust the lefthand stopbolt in the Item Nomenclature
pilots pedal support so that the stop
CM702 Lockwire CRES
just comes in contact with the link
assembly (View A).
Special Tools
(13). Remove the rigging pin assembly and (Ref. Section 910000)
adjust righthand stopbolt in the Item Nomenclature
pilots pedal support. ST601 Rigging pin
(14). Apply full right pedal until the rigging
pin assembly can be inserted through NOTE:
the bracket assembly upper hole and D Thruster control rigging to be accom-
into the slot marked R in the gear plished with the splitter spring installed,
pinion rack Sta. 113.00 splitter assem- the fan pitch control rigging completed,
bly (View D). the tailboom sector control rod assembly
(15). Adjust the righthand stopbolt in the and stationary thruster cone installed.
pilots pedal support so that the stop D Do not adjust the control rodend beyond
just comes in contact with the link the witness hole, do not tighten jamnuts
assembly (View A). until after final adjustment.
NOTE: For dual installation, adjust the stop (1). Insert rigging pin (ST601) into the
bolts in the copilots support bracket to bracket assembly lower rigging hole
match the pilots pedal travel. Repeat steps and through the slot on the pinion gear
(11). thru (13). rack Sta. 113.00 splitter assembly (View
D).
4. AntiTorque Pedal Friction Installation
and Adjustment (2). Removed pan cover.
(3). Adjust rodend until it can be attached
(Ref. Figure 403)
to input clevis of sector assembly (View
(1). Using two pieces of wood and Cclamp C).
or rope, secure pilots pedals in mid (4). Connect sector clevis control rod.
position so they are aligned within 0.50
inch (1.27 cm) of each other. (5). Install bushing, washer and bolt.
Torque bolt 30 40 inchpounds (3.39
(2). Install washer, bolt, bushing, and link 4.52 Nm). Safety wire (CM702) bolt
assembly to bracket assembly on (Ref. AntiTorque Flight Control
instrument console. Installation).
(3). Install brace and clamp arm assembly (6). Remove rigging pin from splitter
to antitorque tube assembly. assembly.
(4). Install friction disc, link, retainer and NOTE: Removed safety clips from turnbuckles
spring, install washer (shim washers if are not to be reused.
required) and nut.
(7). Remove safety clips and adjust the two
(5). Torque brace and arm assembly bolts turnbuckles until a second rigging pin
30 35 inchpounds (3.39 3.95 (ST601) can be inserted through a slot
Nm). Torque nut against washer to in the output drum assembly and
obtain a pedal friction of 5 8 pounds through holes in drum output support
(2.27 3.63 kg). (View A and B).
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672030 Revision 30
MAINTENANCE MANUAL
CABLE
SAFETY CLIPS
500N
500N
CABLE
SAFETY CLIPS
600N
600N
G6720141
Figure 503. Thruster Control Rigging (Sheet 1 of 2)
Page 506
Revision 18 672030
MAINTENANCE MANUAL
RIGGING PIN
INPUT SECTOR
PAN COVER
ROD ASSEMBLY
PAN
RACK GEAR
ROTATING STATIONARY
THRUSTER CONE THRUSTER CONE
SLOT
0.00 +0.25 IN.
(0.00 +6.4 MM) VIEW LOOKING FORWARD
PINION GEAR RIGGING PIN
600N THRUSTER OPENING
G6720142C
Figure 503. Thruster Control Rigging (Sheet 2 of 2)

(8). Using a cable tensiometer, adjust cable (12). Safety wire (CM702) bolts.
tension to 20 40 pounds (9.07
18.14 kg). (13). Thruster Control Rigging shall produce
the following results:
NOTE: Removed safety clips from turnbuckles
are not to be reused. (a). Full left pedal; rotating thruster cone
to be fully open to the left side of the
(9). Install safety clips in turnbuckles. tailboom.
(10). Remove rigging pins. (b). Full right pedal; rotating thruster
cone to be open a minimum of 11.80
(11). Install rotating thruster cone using inches (29.97 cm) when measured
three bolts and washers. Torque bolts from the lower edge of the right
70 90 inchpounds (7.91 10.17 opening to the upper lip of the
Nm). rotating cone.
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672030 Revision 26
MAINTENANCE MANUAL
6. Thruster Control Rigging (600N) (8). Using a cable tensiometer, adjust cable
tension to 20 40 pounds (9.07
(Ref. Figure 503) 18.14 Kg) by adjusting the two turn-
buckles.
Consumable Materials (9). Remove rigging pins.

Item Nomenclature (10). Install rotating thruster cone using
CM701 Lockwire CRES three bolts and washers.
(11). Push full left pedal and verify bottom
Special Tools edge of rotating thruster opening is
(Ref. Section 910000) within 0.00 0.25 inch (0.0 6.4 mm) of
Item Nomenclature edge of stationary thruster cone (Ref.
ST601 Rigging pin Figure 503); adjust turnbuckles as
necessary.
NOTE: Do not adjust the control rodend beyond (12). Remove rotating thruster cone.
the witness hole, do not tighten jamnuts un-
til after final adjustment. (13). Verify cable tension.
(14). Reinstall rotating thruster cone; Torque
(1). Insert rigging pin (ST601) into bracket rotating thruster cone bolts to 70 90
assembly lower rigging hole and inchpounds (7.91 10.17 Nm).
through slot on the pinion gear Sta.
113.00 splitter assembly (Ref. NOTE: On the 600N helicopter, the pedal po-
Figure 503). tentiometer rigging must be checked any
(2). Removed pan cover. justed.
(15). Safety bolts with lockwire (CM701).
(3). Adjust rodend until it can be attached
to input clevis of sector assembly and (16). Safety turnbuckles with clips.
the rigging slot in input sector assem-
bly aligns with the rigging hole in pan. 7. Left Vertical Stabilizer Assembly Rigging
(500N, and 600N with YSAS)
(4). Connect sector clevis control rod.
(Ref. Figure 504)
(5). Install bushing, washer and bolt.
Special Tools
Torque bolt 70 90 inchpounds (7.91
10.17 Nm). Safety bolt with lockwire
Item Nomenclature
(CM701) (Ref. AntiTorque Flight
ST601 Rigging pin
Control Installation).
(6). Reinstall pan cover ensuring rigging NOTE:

pin hole in pan cover aligns with D Rigging to be accomplished with the tail-
rigging hole in sector assembly. If pin boom and vertical stabilizers, splitter as-
cannot be inserted through fan cover, sembly bungee spring and engine air inlet
sector assembly and pan, repeat above fairings installed.
steps.
D Do not adjust the control rodend beyond
the witness hole, do not tighten jamnuts
(7). Adjust the two turnbuckles until a until after final adjustment.
second rigging pin can be inserted
through a slot in the output drum (1). 500N helicopters: Insert rigging pin
assembly and through holes in drum (ST601) into the bracket assembly
output support. upper hole and into the slot marked
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Revision 30 672030
MAINTENANCE MANUAL
R in the gear pinion rack Sta. 113.00 NOTE: The actuator and control tube can be
splitter assembly (View A) splitter slid out the horizontal stabilizer end panel
assembly upper hole. far enough to remove safety wire and loosen
the jamnuts. The control tube can be rotated
(a). Adjust the left vertical stabilizer to and adjusted similar to a turnbuckle.
6.5 0.5 degrees on the horizontal
stabilizer degree plate (View C). (6). 500N helicopters: Using the top rig
plate, adjust right vertical stabilizer to
(b). Remove rigging pin. 4.0 0.5 degrees.
(7). 600N helicopters: Using the top rig
(2). 600N helicopters: With pedals set to full plate, adjust top right vertical stabilizer
right position, adjust tip of the left to 1.75 0.25 degrees.
vertical stabilizer trailing edge to 12
degrees. (8). After adjustment, slide actuator and
control tube out far enough to tighten
(3). Check witness holes for proper thread and safety jamnuts.
engagement. Rodends are to be
installed equal distance on torque tube (9). Reinstall actuator and control tube.
to within 0.020 inch (0.508 mm) of each
other.
NOTE: On the 600N helicopter, the pedal po-
tentiometer rigging must be checked any
8. Stability Augmentation System Rigging justed.
Instructions (500N, and 600N with YSAS)
9. Vertical Stabilizer Assembly Rigging
(Ref. Figure 505) (600N without YSAS System)
(Ref. Figure 506)
Special Tools
Item Nomenclature Special Tools
ST1013 Yaw S.A.S. test box Item Nomenclature
ST601 Rigging pin
(1). Turn OFF power supply, turn S.A.S.
switch on the instrument panel to the NOTE:
OFF position.
D Rigging to be accomplished with the tail-
(2). Install the Yaw S.A.S (ST1013). Test boom and vertical stabilizers installed.
Box to the computer located and D Do not adjust the control rodend beyond
mounted on the copilots seat structure the witness hole, do not tighten jamnuts
forward bulkhead, the test box is now until after final adjustment.
in series with the computer and
actuator. (1). Insert rigging pin (ST601) into the
bracket assembly upper hole and into
(3). Using the aircraft power supply or an the slot marked R in the gear pinion
external power source, activate S.A.S. rack Sta. 113.00 splitter assembly.
switch. (2). Push trailing edge of left vertical
stabilizer to the right using only enough
(4). Adjust actuator to the fully extended force to eliminate freeplay (5lb (0.3
position using the Yaw S.A.S. test box. Kg) max).
(5). Turn aircraft power OFF, actuator (3). Adjust control rod for the left vertical
should remain in fully extended stabilizer to 10.5 0.5 degrees on the
position. horizontal stabilizer degree plate.
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MAINTENANCE MANUAL
HORIZONTAL
STABILIZER
6.5 0.5 VERTICAL STABILIZER
INCIDENCE (LEFT)
ANGLE
(TOP VIEW)
0 500N9901
RIGGING PIN
500N SHOWN
CONTROL TUBE
(LEFT)
AFT CONTROL
ROD
STA 273.00
BELLCRANK
(TOP VIEW)
G672012A
Figure 504. Left Vertical Stabilizer Rigging (500N, and 600N with YSAS)
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MAINTENANCE MANUAL
4.00.5 DEGREES
COMPUTER AND
RATE GYRO
RIGHT CONTROL ROD VIEW LOOKING DOWN
S.A.S. ACTUATOR
STABILITY AUGMENTATION
SYSTEM
RIG PLATE
(VIEW LOOKING DOWN)
500N
G6720151A
Figure 505. Stability Augmentation System S.A.S. (Sheet 1 of 2)
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672030 Revision 30
MAINTENANCE MANUAL
1.75 0.25 DEGREES
BL 0.00
COMPUTER AND
RATE GYRO VIEW LOOKING DOWN
RIGHT CONTROL ROD
S.A.S. ACTUATOR
3 2 1 0 1 2 3
3
2
1
0
1
2
37.07 IN.
3
(94.15 CM)
STABILITY AUGMENTATION
SYSTEM
RIG PLATE
(VIEW LOOKING DOWN)
BL 0.00
600N
G6720152A
Figure 505. Stability Augmentation System S.A.S. (Sheet 2 of 2)
Page 512
Revision 36 672030
MAINTENANCE MANUAL
10.5+0.5 14.5+0.5
DEGREES DEGREES
RIGHT
LEFT CONTROL
CONTROL TUBE
TUBE
CL
LH RH
INCREASE PRESSURE L PEDAL INCREASE PRESSURE R PEDAL

BOTTOM VIEW
DECREASE PRESSURE R PEDAL DECREASE PRESSURE L PEDAL
DECREASE PRESSURE L PEDAL DECREASE PRESSURE R PEDAL
INCREASE PRESSURE R PEDAL INCREASE PRESSURE R PEDAL
TRIM TAB ADJUSTMENT
6G670921A
Figure 506. Vertical Stabilizer Rigging (600N without YSAS)
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672030 Revision 30
MAINTENANCE MANUAL
(4). Push trailing edge of right vertical (c). File smooth all surfaces of spacer and
stabilizer to the right using only enough plates.
force to eliminate freeplay, 5 lbs (0.3
Kg) maximum. (d). Chamfer one 9.00 inch (22.86 cm)
edge of each plate, 0.060 x 0.100 inch
(5). Adjust control rod for the right vertical (1.524 x 2.54 mm) (this will be the
stabilizer to 14.5 0.5 degrees on the front of the tool) as indicated in
horizontal stabilizer degree plate. Figure 507.
(6). Remove rigging pin. (e). Stack plates, chamfered edges facing
each other with spacer between
NOTE: On the 600N helicopter, the pedal po- plates and flush with aft side of
tentiometer rigging must be checked any plates (unchamfered edge).
justed. (f). Drill and rivet angle tool together,
size and type of rivets optional.
10. Vertical Stabilizer Trim Tab Adjustment
B. Trim Tab Adjustment
and Tool Manufacturing (600N without
YSAS) (Ref. Figure 506) Adjust vertical stabilizer trim
tabs to improve directional handling character-
A. Trim Tab Tool Manufacturing istics and to minimize pedal forces in forward
flight.
(Ref. Figure 507)
For best results, aircraft should be weighted
(1). Manufacture guide as follows: down to normal operating weight during test
(a). Cut guide from 0.130 inch (3.30 mm) flights while doing tab adjustments.
2024T3 aluminum sheet 7.00 inch NOTE:
(17.78 cm) x 4.50 inch (11.43 cm).
D Ensure vertical stabilizers are rigged cor-
(b). Measuring 1.73 inch (4.39 cm) from rectly (Ref. Vertical Stabilizer Assembly
bottom, make Vcut in guide 1.030 Rigging (600N)).
inch (2.62 cm) wide and 3.79 inch D Ensure there is no play between the
(9.63 cm) deep. 500N72135 bellcrank assembly and the
500N72123 shaft.
(c). File 0.070 inch (1.78 mm) wide x
0.260 inch (6.60 mm) deep slot in aft D Ensure there is minimal play between the
end of Vcut. upper and lower vertical stabilizers.
D When installing new upper vertical stabi-
(d). File smooth all surfaces of guide. lizers, if previous tab settings were not re-
corded, left trim tab should be set to zero
NOTE: Note the difference in the degree mark-
degrees and right trim tab should be set
ings between the top and bottom of the
to 10 right (viewed looking forward from
guide.
the rear).
(e). Etch degree marks in guide as D The right vertical stabilizer tends to af-
indicated in Figure 507. fect pedal pressure more than the left.
The left vertical stabilizer tends to affect
(2). Manufacture angle tool as follows: flight characteristics more than the right.
(a). Cut two plates from 0.130 inch (3.30
Left Vertical Tab Right Vertical Tab
mm) 2024T3 aluminum sheet 9.00
inch (22.86 cm) x 2.00 inch (5.08 cm). 0 10 Right
(b). Cut a spacer from 0.040 inch (1.016 (1). Determine which pedal requires excess
mm) 2024T3 aluminum sheet 9.00 pressure to attain proper trim during
inch (22.86 cm) x 1.00 inch (2.54 cm). straight flight.
Page 514
Revision 30 672030
MAINTENANCE MANUAL
20
0.050 IN.
10 (12.70 MM)
0
10 RIVETS
20 (4 PLCS)
THIS SIDE UP
9.00 IN.
(22.86 CM)
4.05 IN.
(10.29 CM)
3.79 IN.
(9.63 CM)
4.50 IN
(11.43 CM)
20
10
1.03 IN. (2.62 CM) 0
10
0.07 IN.
(1.78 MM) 20
1.73 IN. 0.0600.100 IN.
(4.40 CM) R
THIS SIDE DOWN (1.5242.54 MM) 0.130 IN.
(3.302 MM)
MAX
7.00 IN. 0.040 IN.

(17.78 CM) (1.016 MM) 2.00 IN. 1.00 IN.
GUIDE (5.08 CM) (2.54 CM)
6G670922
Figure 507. Vertical Stabilizer Trim Tab Bending Tool

NOTE: Do not bend tabs beyond 20 in
CAUTION either positive or negative direc-
D Always adjust right vertical stabilizer tion. Tabs and/or vertical stabilizer skin can
trim tab first. If tab is bent to a maximum be damaged.
of 20 before correct pedal pressure can be
achieved, go to left tab and continue ad- NOTE:
justments. D Bending tabs to the right will decrease
left pedal pressure.
D Limit tab adjustments to 5 increments
D Tab angles are acceptable when left pedal
between flights.
forces are between 2 and 5 lbs. (0.91 and
2.27 Kg) in stabilized flight and the flight
D Exceeding 20 tab adjustments may cause
characteristics are acceptable.
a "tail wag" condition.
(4). Bend tab in direction needed to relieve
pedal pressure and improve flight
(2). Position guide on right vertical stabiliz- characteristics.
er over trim tab.
(5). Remove tab tools and fly aircraft, see
chart below, to determine if pedal
(3). Position angle tool on trim tab. pressure was relieved.
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MAINTENANCE MANUAL
(6). Repeat above steps until pedal pressure Pedal Position Pedal Force
and handling characteristic are cor-
rected. Hover
*60 KIAS
NOTE: After trim tab adjustments, position
guide on both the top and bottom of trim tab *80 KIAS
to ensure tab is straight. *100 KIAS
(7). Log trim tab setting in log book. *120 KIAS
*130 KIAS
NOTE: *Level flight
Handling: Low pedal forces might require bending
tabs in opposite directions.
Table 501. Flight Controls Troubleshooting
Pedal KickThru or Binding
Noticeable hump in pedals (kickthru) in flight.
yes
Are control cables Binding? no Is there binding in control rod at no Is there pedal binding in flight?
fan transmission?
yes yes yes
Replace worn or binding Adjust control rod for proper Check for dry roller bearings at
control cable(s). clearance. rotating cone.
Dutch Roll
Is there relative movement no Is there play when holding cone no Bend left tab to the left, starting
between upper and lower and moving the vertical with 5 left.
verticals? stabilizers?
yes yes
Check for loose attaching Check for loose bellcrank at
hardware for the upper and control shaft.
lower verticals (NOTE).
NOTE: When tightening hardware, do not torque fasteners beyond specified torque limits.
Page 516
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MAINTENANCE MANUAL

INSPECTION/CHECK
1. Upper Fuselage and Tailboom Control (4). Inspect control rod fitting, torque tube
Linkage Inspection mounting bracket and pedal mounting
bracket for cracks and corrosion. Using
(Ref. Figure 401) an 8X magnifying glass, mirror and
flashlight, closely inspect pedal link
(1). Inspect rod end bearings for binding bellcrank fitting of pedal bracket in
and excessive wear (0.040 inch (1.016 center forward area where fitting (fork
mm) maximum axial play). Inspect piece) joins tubular section. If any
rivet at fixed rod end. cracks are detected, replace bracket
assembly. Inspect bracket bearings for
(2). Inspect control rod for surface damage excessive looseness.
and evidence of bending.
(5). Inspect torque tube for cracks,
(3). Inspect rubber boot just forward of Sta. scratches, nicks, dents and similar
137.50 bulkhead for condition. surface defects.
(4). Inspect control rod surfaces serviceabil- (6). Inspect pedal brackets for corrosion.
ity, wear is limited to thickness of hard
anodic coating. 3. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Inspection
(5). Inspect bellcranks for scratches, cracks, (1). Inspect bellcrank and support bracket
corrosion and similar surface defects. for cracks, corrosion and other similar
Check that all bushings are secure. surface defects.
(6). Inspect bellcrank bearings for looseness (2). Check that all bushings are secure.
and binding. Check bellcrank bearings for looseness
and binding.
(7). Visually inspect bellcrank supports for
cracking/damage. (3). Inspect rod ends bearings for binding
and excessive wear (0.040 inch (1.016
2. AntiTorque Pedal Assembly Inspection mm) maximum axial play). Inspect
control rod surface serviceability, wear
(Ref. Figure 502) is limited to thickness of hard anodic
coating. Inspect for safety wire at
NOTE: Inspect components at left and right po- rodends and lockwasher as required.
sition on the righthand command models. Bolts for cotter pins as required.
Check that corresponding pedals contact
stops simultaneously. 4. Forward and Intermediate Directional
Control Tube, and Link Inspection
(1). Inspect pedals and pedal arms for
(1). Inspect rodend and link bearings for
cracks, elongated pedal attach holes
binding and excessive wear (0.040 inch
and open drain holes. Inspect teflon
(1.016 mm) maximum axial play).
reinforced bushing liners for deteriora-
tion. (2). Inspect control tubes and link for
surface damage and wear. Inspect
(2). Inspect pedaltoarm quickrelease control tubes surface serviceability,
locking pin for condition and positive wear is limited to thickness of hard
spring action. anodic coating.
(3). Inspect links and bellcrank for cracks (3). Inspect for safety wire at rodends and
and bends, and bearings for excessive lockwasher as required. Bolts for cotter
play. pins as required.
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672030 Revision 34
MAINTENANCE MANUAL
5. Splitter Bungee Spring Inspection (500N) and female connectors for corrosion
pitting or cracks; none allowed.
(1). Inspect spring support bracket for loose
rivets, loose screws, corrosion and (8). Inspect center cable hex end for wear
cracks and general condition. beyond allowable tolerance (Ref.
Figure 601).
(2). Check link assemblies for cracks, bends (9). Inspect collar for wear in locking
and dents. groove.
(3). Inspect spring for condition and a (10). Inspect relieved area, at Sta. 123.30,
positive spring action. between threads and swage for crack or
evidence of corrosion.
6. Sta. 113.00 Splitter Assembly and
Bellcrank Inspection (11). Inspect relieved area, at Sta. 164.00
(500N) or Sta. 292.00 (600N), between
(1). Visually inspect bellcrank and support threads and swage for crack or evidence
bracket for cracks and damage using 5X of corrosion.
power magnifying glass. (12). Inspect forward cable coupling opening
(2). Inspect for cracks, corrosion and other for proper dimension (Ref. Figure 601).
similar surface defects. (13). Using a bright light and 10x magnify-
ing glass, inspect the swaged area of
(3). Check that all bushings and bearings the telescopic swivel end for cracks
are secure. (Ref. Figure 603).
(4). Inspect rodend bearings for binding and (14). Inspect for any evidence of swivel ball
excessive wear (0.040 inch (1.016 mm) separation.
maximum axial play). Inspect control
rod surface serviceability, wear is 8. YSAS Actuator, Rate Gyro and Electronic
limited to thickness of hard anodic Control Box Inspection
coating. Inspect for safety wire at (1). Inspect YSAS actuator for damage, no
rodends and lockwasher as required. damage allowed.
Bolts for cotter pins as required.
(2). Inspect mounting hardware for proper
7. Forward and Center Cable Assembly installation and general condition.
Inspection (3). Inspect wiring for condition, no fraying,
cracking of insulation or chafing
(1). Inspect for freedom of movement and
allowed.
no binding.
(4). Inspect grommet for proper installation
(2). Check rodend bearings for corrosion, and deterioration, replace if deterio-
and wear. rated.
(3). Cable housing for fraying, and security. (5). Inspect mounting bracket for cracks
(pay particular attention to area around
(4). Inspect cable couplings for wear, four rivet attach holes) no cracks
deformation or damage (Ref. allowed.
Figure 602).
(6). Inspect rate gyro and electronic control
(5). Inspect inner cable coupling hex for box for damage, security in mount and
proper alignment with outer cable ensure electrical plugs are secure.
coupling. (7). Inspect mounting bracket for cracks, no
(6). Inspect cable inner couplings for cracks allowed.
deformation or obvious damage. 9. Fan Pitch Control Tube Inspection
(7). Using a bright light and 10X magnify- (1). Inspect tube for dents, scratches, nicks,
ing glass, inspect inner coupling male gouges and corrosion, none allowed.
Page 602
Revision 35 672030
MAINTENANCE MANUAL
(2). Inspect for visible step in splined area. (b). Minimum measurement across pins
(3). If step is evident: is 0.640 in. (16.256 mm).
(a). Measure across splines using 0.096
in. (2.4384 mm) diameter pins.
Table 601. Isolating Control System Troubles
Binding, lockingup and erratic Disconnect fwd control tube from If symptom is gone, check from
action of foot pedals (Do not force Sta. 113.00 splitter assembly. splitter assembly aft.
controls).
0.250 INCH (6.35 MM)

HEX (REF)
CLOSED OPEN
POSITION POSITION
(REF TABLE)
HEX CONFIGURATION
FORWARD CABLE FEMALE END
ROUND CONFIGURATION ACCEPTABLE DIMENSIONS

CENTER CABLE (5) (INSIDE TAIL BOOM) SLOT DIMENSION MALE CONNECTOR
IN (MM)
0.260 IN. (6.604 MM) MIN. 0.450 (11.43) HEX CONFIGURATION
(NOTE) 0.685 (17.40) ROUND CONFIGURATION
0.450 (11.43) ROUND CONFIGURATION
0.250 IN. UNACCEPTABLE DIMENSIONS
(6.35 MM)
0.685 (17.40) HEX CONFIGURATION
DIMENSION ACROSS HEX

(ROTATED)
NOTE: WHEN DIMENSION REACHES 0.260 IN. (6.604 MM) ACROSS ANY
TWO OPPOSING POINTS OF HEX, CABLE HAS REACHED ITS MAXIMUM
WEAR AND MUST BE REPLACED WITH A SERVICEABLE CABLE. G672020B
Figure 601. Control Cable Coupling Inspection
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672030 Revision 39
MAINTENANCE MANUAL
TAILBOOM FAIRING
CABLE ASSY
RELIEF AREA
INSPECT FOR CRACK
INNER FEMALE
CONNECTOR
OUTSIDE COLLAR SLEEVE CABLE END RELIEF AREA

(MUST BE FIRMLY LOCKED
IN PLACE BEFORE TAILBOOM
FAIRING IS INSTALLED)
INNER MALE
CONNECTOR
INNER COUPLING CONNECTOR
88_776
Figure 602. Forward and Center Cable Relief Area Inspection
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Revision 24 672030
MAINTENANCE MANUAL
FORWARD CABLE
TAILBOOM FAIRING
CENTER CABLE
ASSY
INSPECT TELESCOPIC SWIVEL END

FOR CRACKS AND/OR TELECOPTIC
SWIVEL SEPERATION FROM
THRUSTER CABLE CONDUIT CAP
TELESCOPIC SWIVEL END

CONDUIT CAP
88_777
Figure 603. Control Cable Telescopic Swivel End Inspection
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672030 Revision 24
MAINTENANCE MANUAL
10. Sector Assembly, Control Cables and (a). Fraying or corrosion; no fraying or
Drum Assembly Inspection corrosion allowed.
(Ref. Figure 402) (b). Proper installation of turnbuckle
safety clips.
(1). Inspect sector assembly for:
(c). Corrosion or cracking on turnbuckles;
(a). Proper installation of mounting
no corrosion or cracking allowed.
hardware.
(b). Remove access cover from pan (d). Proper cable tension.
assembly. (6). Reinstall access cover on top of station-
(c). Center cable mounting bolt for ary thruster assembly (600N).
security and proper installation of
(7). Inspect control cable pulleys for:
safety wire.
In the following step, ensure (a). Proper installation of mounting
WARNING the antitorque pedals are hardware.
not moved, personal injury can occur. (b). Guard pins installed.
(d). Check sector assembly for excess (c). Excessive groove in pulleys; evident
upanddown play. in outofround pulley.
(e). Damage, cracks or corrosion; no
(8). Inspect drum assembly for:
damage, cracks or corrosion allowed.
(f). Reinstall access cover on pan assem- (a). Proper installation of mounting
bly. hardware.
(2). Remove tip cap (500N). (b). Damage, cracks or corrosion; no

damage, cracks or corrosion allowed.
(3). Remove rotating cone assembly.
(c). Guard pins installed.
(4). Remove access cover from top of
stationary thruster assembly (600N). (9). Reinstall rotating cone assembly.
(5). Inspect control cables for: (10). Reinstall tip cap (500N).
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Revision 39 672030
MAINTENANCE MANUAL

REPAIRS
1. AntiTorque Flight Control Repair have equal space for angular throw;
General tighten jamnut.
Use care when drilling to re- (6). If removed, install rivet to secure
CAUTION move or install riveted rod end; rodend.
rod end is steel and rod and bearing adapter
(7). Ensure slotted bushing is in place.
are aluminum.
(8). Secure control rod in torque tube fitting
2. Sta. 97.50 (500N) or Sta. 95 (600N) or idler bellcrank with bolt, two
Bellcrank and Support Bracket Repair washers, nut and cotter pin.
4. Upper Fuselage Sta. 113.00 Splitter
Consumable Materials Assembly Repair
Item Nomenclature Refer to Field Service Department for repairs.
CM321 Surface primer locking compound 5. Intermediate Control Tube Repair
(1). Perform straightness check on inter-
(1). Replace unserviceable bearings. mediate control rod that appears bent
or bowed. Total length of control rod
(2). Install new bearings with surface (excluding rod ends) must be straight
primer (CM321) and grade A locking within 0.040 inch (1.016 mm), with
compound (CM431). straightness variation limited to
maximum of 0.010 inch (0.254 mm) in
NOTE: When idler bellcrank bearing are re- each foot of length.
placed, ensure idler bellcrank spacers are
reinstalled between bearings. NOTE:
D A dye check for cracking must always be
(3). Replace bellcranks or control support performed after coldstraightening. Re-
brackets that have cracks or enlongated place cracked rod, or cracked or bent rod
holes. end.
3. Forward Directional Control Tube Repair D Do not use rod ends to support rod during
straightening process.
(2). Coldstraighten bent rod that is not
play is more than 0.040 inch (1.016
within tolerance provided there are no
mm). Set initial control rod length and
nicks or sharp dents in bend length.
bearing angularity.
(2). Initial length forward directional play is more than 0.040 inch (1.016
control tube is 15.42 inches (39.17 cm). mm). Set initial control rod length and
Rod end angularity is 0 degrees bearing angularity.
straight line within 2 degrees.
(4). Replace unserviceable control rod
(3). Perform straightness check on control bearing adapter if installed.
rods that appear bent or bowed.
(a). Measure length and record position
(4). Drill out rivet. Loosen jamnut and of rod end in adapter.
unscrew rodend.
(b). Remove affected rod end. Initial
(5). Screw replacement rodend into rod to installation length of intermediate
obtain same measurement made in step control rod is 23.68 inches (60.15 cm).
b. Align control rodends so bearings Rod end angularity is 40 2 degrees.
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672030 Revision 18
MAINTENANCE MANUAL
(c). Drill out rivets securing adapter to (8). Repair minor surface defects such as
rod and aft rod end. scratches, nicks and corrosion on
bellcranks and support bracket.
(d). Install rod end in replacement
adapter and position at recorded (9). Use abrasive cloth (CM802), grade 400
measurement. 600, to smooth out and blend in such
defects.
6. Sta. 137.50 Support Bracket and Bellcrank (10). Cast surfaces may be reworked to depth
Repair of 0.020 inch (0.508 mm).
(11). Repair surface abrasion on control rod
Consumable Materials by smoothing area with grade 400
(Ref. Section 910000) abrasive cloth (CM802) and restoring
Item Nomenclature protective finish with primer (CM318).
CM318 Primer (12). Replace rod if wear or depth of repair
CM321 Surface primer locking compound exceeds 0.004 inch (0.102 mm).
CM802 Abrasive cloth, aluminum oxide (13). Replace tailboom control rod if hard
anodic coating is worn through and
aluminum base metal is visible.
(1). Replace unserviceable bearings.
(14). Replace split or torn boot.
(2). Install new bearings with surface
primer (CM321) and grade A locking 7. Fan Pitch Control Tube Repair
compound (CM431).
Refer to Field Service Department for repairs.
(3). Flat machined surfaces, except clevis 8. Forward Cable Assembly Repair
inner ears, may be reworked to depth of
0.015 inch (0.381 mm). Refer to Field Service Department for repairs.
(4). Clevis inner ear surfaces may be 9. Center Cable Assembly Repair
reworked to depth of 0.020 inch (0.508
mm). Refer to Field Service Department for repairs.
10. Aft Control Rod Repair
(5). Machined holes may have 0.003 inch
(0.076 mm) removed from bore wall in Refer to Field Service Department for repairs.
an area no greater than 15 percent of
circumference and 50 percent of depth. 11. Thruster Sector Assembly Repair
(6). All edges may have 0.030 inch (0.762 Refer to Field Service Department for repairs.
12. Drum Assembly and Idler Pulleys Repair
holes, which are limited to 0.010 inch
(0.254 mm) chamfer. Refer to Field Service Department for repairs.
(7). All rework must be smoothly blended 13. AntiTorque Pedal Disassembly
into adjacent surfaces and finish must
be restored. (Ref. Figure 403)
NOTE: Before disassembly of pedal installa-
NOTE: Installation direction of Sta. 137.50 tion, matchmark mating pedal arms, links
bellcrank bearing may be from either side, and bellcranks with pedal brackets to avoid
depending on location of bearing shoulder. intermixing components between locations
There must not be less than 0.010 inch at reassembly.
(0.254 mm) protrusion of bearing inner race
beyond sides of bellcrank after bearing is in- (1). Disconnect links from pedal arms and
stalled. bellcrank; remove links.
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Revision 18 672030
MAINTENANCE MANUAL
(2). Remove bellcrank from pedal bracket. Right pedal arm bushings are
CAUTION glassfilled phenolic. Do not
(3). Remove nut and washer of two bushing cock bushings during replacement; ensure
assemblies that secure left pedal arm bushing is fully seated in arm bore. Keep
and control rod fitting to torque tube. tools from contact with bushing liners to
avoid fraying.
(4). Carefully remove bushing bolt and
temporarily reinstall washer and nut (6). Replace bearings in right pedal arm
on bolt. when teflonreinforced liner is galled or
frayed. Pull bushing to remove; press to
(5). Slide pedal bracket and pedal arms off install.
end of torque tube.
(7). Remove corrosion from pedal brackets
NOTE: (Ref. Sec. 204000 and CSPA3,
D Do not remove two teflonlined bushings Corrosion Control Manual).
from right pedal arm unless replacement
is required. 15. AntiTorque Pedal Reassembly
D Do not remove two stop bolts, jam nuts on (Ref. Figure 403)
stop bolts or bearings from pedal bracket
unless replacement is required. (1). When reassembling components, check
for correct matchmark identification.
(6). Slide torque tube bracket and control
rod fitting off torque tube. (2). If previously removed, thread jamnut
on each of two stop bolts and install two
14. AntiTorque Pedal Repair stop bolts into threaded inserts of pedal
brackets.
Consumable Materials (3). Slide torque tube bracket and control

(Ref. Section 910000) rod fitting onto torque tube.
Item Nomenclature
(4). Locate pedal bracket and pedal arms
CM425 Sealing compound for correct position on torque tube; slide
CM431 Sealing, locking and retaining compound bracket and arms onto torque tube.
(5). Fasten left pedal arm and control rod
(1). Replace parts that are cracked or have fitting to torque tube with adjustable
elongated attachment holes. bushing assemblies.
Do not attempt to straighten
CAUTION bent torque tube or pedal link.
(6). Install bushing bolt so shank at
bolthead end protrudes at least 0.002
(2). Replace unserviceable pedal covers. inch (0.051 mm).
Apply sealing compound (CM425) to (7). Torque nut to 50 80 inchpounds
approximately 30 percent of upper and (5.65 9.04 Nm) plus drag torque; do
lower edge surfaces that contact pedal. not allow bolt to turn.
Cure according to container instruc-
tions. (8). Ensure each end of bushing assembly
shank protrudes a minimum of 0.002
(3). Replace complete pedal link if cracked inch (0.051 mm). If not, loosen and
or contains unserviceable bearings; repeat above steps.
bearings are not replaceable.
(9). Ensure slotted bushing is in place; then
(4). Replace unserviceable bearings in attach bellcrank to pedal bracket with
mounting brackets or pedal link bolt, two washers, nut and cotter pin.
bellcrank.
(10). Ensure slotted bushings are in place;
(5). Install replacement with grade A then fasten each link to bellcrank with
locking compound (CM431). bolt, two washers, nut and cotter pin.
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672030 Revision 18
MAINTENANCE MANUAL
(11). Ensure slotted bushings are in place; (f). Remeasure and record dimension
then fasten each link in pedal arm lugs C.
with bolt, two washers, nut and cotter
pin. (6). Cut lockwire and remove the four
screws that hold the seal housing and
(12). Ensure outboard pedals clear windows splined housing.
by a minimum of 0.20 inch (5.08 mm)
with 20 pounds (9.07 kg) of force NOTE: It may be necessary to grasp the cylin-
applied. drical portion of the seal housing or splined
housing with a rubbertipped clamping tool
16. YSAS Actuator Regrease Procedure to loosen the housing because of primer ap-
plied to the screws at assembly.
A. YSAS Actuator Disassembly
(Ref. Figure 801) (7). If there is an inspection seal at the

housing joint, remove enough of the
Do not attempt to loosen or label so that it cannot get pinched
CAUTION tighten nut by grasping actua- between the housings when the actua-
tor housing, damage to spline housing can tor is reassembled. Leave some of the
occur. label on the actuator to aid in reas-
sembly. If there is no inspection seal,
(1). Cut and remove lockwire from lock- use pieces of tape.
washer and nut.
NOTE: Belleville spring, spacer and shims (if
(2). Hold hex end of output shaft and loosen installed) are installed between the seal
nut. housing and splined housing.
(3). Remove rod end, nut and lockwasher. (8). Remove seal housing and splined
housing.
(4). Record output shaft orientation by
marking the notch on the connector
side of the shaft with a pencil. (9). Note the order of assembly of these
parts.
(5). Measure endplay of the actuator as
follows: (10). Measure and record the thickness of the
spacer and the total thickness of the
(a). Push the output shaft in towards the shims (if installed) to avoid confusion
actuator housing by applying a load with the spacer and shims on the other
of 20 100 lbs (9.07 45.36 kg). side of the splined housing.
(b). Using a depth gage, measure and NOTE: The teflon washer attached to the end of
record dimension C. the LVDT core is a close fit to the bore
through the LVDT housing, it may be neces-
(c). Screw the rod end into the output sary to carefully tug a little to fully remove
shaft a few turns. the shaft.
(d). Pull on the output shaft by applying
a load of 20 100 lbs (9.07 45.36 (11). Unscrew and remove the output shaft.
kg). This shaft has the LVDT core and
associated hardware attached to it; Do
(e). Unscrew and remove the rod end not unscrew the nylon screw or the
without changing dimension C. LVDT core.
NOTE: If the variation in dimension C ex- (12). Note the orientation of the belleville
ceeds 0.013 inch (0.3302 mm), the actuator spring, spacer and shims (if installed).
should be returned to the manufacturer for Measure and record the thickness of the
repair rather than regrease. spacer and shims.
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Revision 42 672030
MAINTENANCE MANUAL
Do not use any cleaning sol- NOTE: If you mix grease, only use Mobil
CAUTION vents. Damage to the motor Grease 28 which meets MILG81322.
bearings and the molybdenum disulfide fin-
ish on the acme nut and spline surfaces may (4). If necessary, mix 95% aircraft grease
occur. (CM111) with 5% molybdenum disulfide
powder (CM109) by weight.
(13). Wipe off old grease from all parts using
lintfree cloth. (5). Apply special grease (CM127) to acme
screw threads until scale is balanced
(14). Using cotton swabs, remove grease again.
from acme nut area. Be sure to reach
into the cavity just beyond the acme (6). Evenly distribute grease around the
nut threads to remove grease deposits. acme screw threads to form a fairly
even cylinder in order to fit through the
(15). Use the acme screw to remove grease belleville spring without scraping off
from the acme nut threads. too much grease.
(a). Run screw in and out, then wipe (7). With belleville spring, spacer and shims
threads clean. (if installed) in place within end bore in
motor housing, carefully assemble
(b). Repeat above step until no more greased output shaft to actuator.
grease appears on screw threads.
(a). Screw in the shaft until the leading
B. YSAS Actuator Regrease and edge of the spline on the shaft is
Reassembly about flush with the end of the motor
housing and oriented so that the
(Ref. Figure 801) splined housing can be put on in its
proper orientation.
Consumable Materials (8). Apply grease (CM127) to splined
surfaces of splined housing until
Item Nomenclature
grooves are completely full. Install
CM109 Molybdenum disulfide powder lubricant splined housing as originally oriented.
CM127 Grease, YSAS Actuator (9). Apply film of grease (CM127) to
CM318 Primer smallest inside diameter of seal
CM731 Lockwire CRES housing.
(10). With belleville spring, spacer and shims
NOTE: Use YSAS actuator grease (CM127) or (if installed) in place within end bore of
mix aircraft grease (CM111) and molybde- seal housing, slide seal housing into
num disulfide powder (CM109) to regrease position over output shaft as originally
the actuator. oriented.
(1). Prior to applying new grease, reas- (11). Replace four screws which hold down
semble the output shaft with attached seal housing; Use only
hardware (splined housing, belleville NAS135204H8P screws.
spring, spacer and shims (if installed))
to the actuator to avoid confusion at (a). Install screws with wet primer
reassembly. (CM318).
(2). Remove and weigh output shaft with (b). Torque screws to 9 inchpounds
LVDT core and associated hardware (1.02 Nm).
attached; Record weight.
(c). Using lockwire (CM731), safety
(3). Adjust scale up 2.5 grams. screws.
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672030 Revision 42
MAINTENANCE MANUAL
(12). Reinstall rod end, nut and lockwasher (13). Using lockwire (CM731), safety nut to
with rod end face (surface A) oriented lockwasher, washer may be oriented
at 90 2 with respect to surface B. with lockwire end up or down.
(19.21 22.60 Nm).
SPLINED MOTOR

HOUSING HOUSING

SEAL
C HOUSING LVDT CORE
OUTPUT
1.10 0.03 IN SHAFT
(27.9"0.76 MM)
ROD
END
LOCKWASHER
LOCKWIRE
BELLEVILLE
SHIMS SPRING SHIMS
SPACERS SPACERS
SCREW A
SAFETY
WIRE
G672021
Figure 801. YSAS Actuator (CrossSection View)
Page 806
Revision 42 672030
MAINTENANCE MANUAL
Chapter
71
Power Plant
MAINTENANCE MANUAL
TABLE OF CONTENTS
710000 Power Plant (250C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Power Plant Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Power Plant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Models 250C20B and 250C20R/2 Power Plant Fault Isolation . . . . . . . . . . . . . . . 1
Table 1. Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Engine Disconnecting for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Allison 250C20B and 250C20R/2 Engine Removal and
Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Removal of Disconnected Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
2. Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. Model 250C20B and 250C20R/2 Engine Stripping and
Buildup (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3. Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 403. Model 250C20B and 250C20R/2 Engine Mounts and
Airframe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
4. Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
5. Modification of Accessory Drive Gearbox Overboard Vent Tube
(SN 0004D 0519D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 404. Extension of Engine Accessory Drive Overboard Vent Tube . . . . . . 413
710030 Power Plant (250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
3. Model 250C30 Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Model 250C30 Engine Removal and Installation (Sheet 1 of 2) . . 402
2. Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
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B. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. Engine Mounts and Structural Fittings . . . . . . . . . . . . . . . . . . . . . . . . 406
3. Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Model 250C30 Engine BuildUp (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 408
4. Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
710047 Power Plant (250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
3. Model 250C47 Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Starter/Generator System Wiring Diagram (Sheet 1 of 2) . . . . . . . . . . 2
Figure 2. Engine Wire Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Model 250C47 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Engine Buildup Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. Engine Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
C. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
D. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Starter/Generator Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 408
2. Model 250C47 Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3. Model 250C47 Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
711000 Engine Air Intake System (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . A
1. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Air Inlet Screen Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Air Inlet Screen Removal (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Air Inlet Screen Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . 202
B. Engine Inlet Screen Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Air Inlet Screen Installation (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Engine Inlet Screen Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Air Inlet Bell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Air Inlet Bell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Air Inlet Bell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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4. Firewall Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Air Intake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Firewall Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Firewall Seal Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Air Inlet Bell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Plenum Chamber Drain Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
711005 Engine Compressor Water Wash Kit (369D/E/FF 500/600N) . . . . . . . . . . A
1. Engine Compressor Water Wash Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Compressor Water Wash Kit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Engine Compressor Water Wash Kit Initial Installation . . . . . . . . . . . . . . . . . . . . . . . 901
A. Gaining Access to Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Airframe Modification and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
2. Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Engine Compressor Water Wash Kit Installation
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
711010 Engine Air Particle Separator (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . A
Table 1. Engine Air Particle Separator Configurations . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1. Particle Separator Operating Principle Early Type
(Donaldson Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Particle Separator Operating Principle Current Type
(APM Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . 101
Figure 101. 369H90148503, 505, 507, 509 Particle Separator
Installation Wiring Diagram (SlimLine Panel) . . . . . . . . . . . . . . . . . . 102
Figure 102. 369H90148503, 505, 507, 509 Particle Separator Installation
Wiring Diagram (TPanel with Center Console) . . . . . . . . . . . . . . . . . . 103
Installation Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 104. 369H90148535,537, 539, 541, 543, 545 and 500N901481, 3
Particle Separator Installation Wiring Diagram . . . . . . . . . . . . . . . . . . 105
1. Air Bypass Door System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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2. Solenoid Air Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Air Pressure Sensing Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Air Bypass Door Rigging (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Air Bypass Door Rigging (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Particle Separator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7. Mist Eliminator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Air Bypass Door System (369D/E/FF) (Sheet 1 of 3) . . . . . . . . . . . . . 204
Figure 202. Air Bypass Door System (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1. PLM Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. PLM Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. PLM Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. PLM Scavenge Ejector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. PLM Scavenge Ejector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. PLM Scavenge Ejector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. PLM Ejector Nozzle and Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4. Mist Eliminator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Helicopters With Mist Eliminator Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Helicopters Without Mist Eliminator Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Mist Eliminator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5. Donaldson Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Donaldson Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Donaldson Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
1. Engine Air Inlet Bypass Door 300Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. PLM Particle Separator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Donaldson Particle Separator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Scavenge Air Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6. Mist Eliminator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . 604
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. PLM Particle Separator Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Vortex Tube Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Displaced Vortex Generator Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Vortex Generator Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
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C. Damaged Or Missing Vortex Generator Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
D. Damaged Or Missing Vortex Generator and Outlet Tubes . . . . . . . . . . . . . . . . . . . 803
E. PLM Particle Separator Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
F. Fairing Modifications (369D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Fairing Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
2. Mist Eliminator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
3. Particle Separator Alignment and Joint Surface Repair (369D/E/FF) . . . . . . . . . . . 805
4. Donaldson Particle Separator Repair (369D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 803. Donaldson Particle Separator Gasket Replacement . . . . . . . . . . . . . . 806
Figure 804. Mist Eliminator Bolt Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
5. Donaldson Particle Separator Auxiliary Fairings and Seals Installation . . . . . . . . 808
Figure 805. Auxiliary Fairings and Seals Installation (Sheet 1 of 2) . . . . . . . . . . 810
Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 1 of 2) . . . . . . . 812
Figure 807. Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
1. Engine Air Particle Separator Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Filter Bypass Door and Aft Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Air Bypass Door Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 902
Figure 902. Aft Cable Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
B. Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
C. Handle and Forward Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
D. Bleed Air System Installation (Helicopters Without Cabin Heat) . . . . . . . . . . . . . 907
E. Bleed Air System Installation (Helicopters With Cabin Heat) . . . . . . . . . . . . . . . . 907
Figure 903. Handle and Forward Cable Installation (Sheet 1 of 3) . . . . . . . . . . . 908
F. Scavenge Air System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
Figure 904. Modifications and Installation (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . 912
G. Solenoid Valve and Pressure Switch Wire Harness Installation . . . . . . . . . . . . . . 916
Figure 905. Scavenge Air Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 917
H. Ejector Duct Doubler and Rib Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918
I. Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918
Figure 906. Ejector Duct Doubler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919
Figure 907. Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920
J. Instrument Panel Modifications; TPedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 922
K. Slimline Panel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 922
L. PostInstallation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923
M. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923
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711060 Engine Air Particle Separator (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . 101
Figure 101. Air Intake and Particle Separator Circuits Wiring Diagram . . . . . . 101
1. Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Scavenge Air Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Scavenge Air Solenoid Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Scavenge Air Solenoid Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Air Filter Bypass Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Air Filter Bypass Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Air Filter Bypass Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Bypass Door Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Bypass Door Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Bypass Door Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5. Bypass Door Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Bypass Door Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Bypass Door Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
6. Bypass Door Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
7. Particle Separator Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Engine Air Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Bypass Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
1. Engine Air Particle Separator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Bypass Door Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Bypass Door Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . 602
712000 Engine Mounts (250C20B, 250C20R/2, 250C30 and 250C47) . . . . . . . . A
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page vi
MAINTENANCE MANUAL

2. Airframe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Airframe Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Lower Engine Mount Replacement (250C20/C20R/2) . . . . . . . . . . . . . . . . . . . . . . . 401
A. Lower Engine Mount Removal (250C20/C20R/2) . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Lower Engine Mount Installation (250C20/C20R/2) . . . . . . . . . . . . . . . . . . . . . . 401
3. Upper Engine Mounts Replacement (250C20/C20R/2) . . . . . . . . . . . . . . . . . . . . . . 401
A. Upper Engine Mounts Removal (250C20/C20R/2) . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Upper Engine Mounts Installation (250C20/C20R/2) . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. 250C20/C20R/2 Engine Mounts and Airframe Fittings . . . . . . . . 402
4. LowerAft Engine Mount Replacement (250C30/C47) . . . . . . . . . . . . . . . . . . . . . . 403
A. LowerAft Engine Mount Removal (250C30/C47) . . . . . . . . . . . . . . . . . . . . . . . . 403
B. LowerAft Engine Mount Installation (250C30/C47) . . . . . . . . . . . . . . . . . . . . . 403
5. Upper Engine Mounts Replacement (250C30/C47) . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Upper Engine Mounts Removal (250C30/C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Upper Engine Mounts Installation (250C30/C47) . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Model 250C30/C47 Engine Mounts and Airframe Fittings . . . . . 405
Inspection/check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Engine Mounts and Fittings Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Upper Engine Mounts Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Engine Mount Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Mount Hole Repair (250C20/20R/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Painted Surfaces Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
713000 Engine Ignition Control System (250C20B, 250C20R/2 and 250C30) A
1. Engine Ignition System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Automatic Reignition System Description and Operation . . . . . . . . . . . . . . . . . . . . . 1
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Engine Ignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Ignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Automatic Reignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 102. Automatic Reignition System Fault Isolation (369D) . . . . . . . . . . . . 102
Table 103. Automatic Reignition System Fault Isolation (369E/FF 500N) . . 103
1. Automatic Reignition System Component Replacement . . . . . . . . . . . . . . . . . . . . . . 401
Page vii
MAINTENANCE MANUAL

A. Automatic Reignition Test Switch (S11) Replacement . . . . . . . . . . . . . . . . . . . . . . 401
B. Armed Light/Switch (XDS9) Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 401
C. Armed Light/Switch (XDS9) Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 401
D. Armed Lights/Switch (XDS9) Display Screen Replacement . . . . . . . . . . . . . . . . . . 401
E. K104/K304 Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
F. CR1/CR2 Diode Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Auto Reignition System Equipment (Sheet 1 of 3) . . . . . . . . . . . . . . 403
Figure 402. Auto Reignition Wiring Diagram (Sheet 1 of 6) . . . . . . . . . . . . . . . . . 406
Figure 403. Auto Reignition Schematic (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . 412
1. Automatic Reignition System Check (with Ground/Air Switch) . . . . . . . . . . . . . . . 601
A. Normal Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Automatic Reignition System Check (without Ground/Air Switch) . . . . . . . . . . . . 601
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Auto Reignition System Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Preparation for Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Instrument Panel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Electrical System Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Relocation of Auto Reignition Controls (Sheet 1 of 2) . . . . . . . . . . . 802
Figure 802. Auto Reignition Rewiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
1. Auto Reignition Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Automatic Reignition System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Diode Isolator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Relay and Switch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
F. Relay and Switch Assembly Installation (TPanel with Center Console) . . . . . . 903
716000 Engine Cooling System (250C20B, 250C20R/2, 250C30 and 250C47) A
1. Engine Cooling System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Cooling System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Engine Cooling System Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Air Cooling System 250C20B and 250C20R/2
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Page viii
MAINTENANCE MANUAL

Figure 202. Engine Air Cooling System 250C30 and 250C47
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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MAINTENANCE MANUAL

Page x
MAINTENANCE MANUAL
Section
710000
Power Plant
(250C20)
MAINTENANCE MANUAL
POWER PLANT
1. Power Plant Description consist of a combined four stage axial
and single stage centrifugal flow
(1). MDHI 369D/E helicopters may be compressor, an annular combustion
powered by either a 250C20B or chamber and a four stage turbine
250C20R/2 turboshaft engine man- system to extract power from the gas. A
ufactured by the Allison Engine twostage gas producer turbine drives
Company Inc. the compressor, gas producer fuel
control, accessory gear train and N1
(2). MDHI 500N helicopter is powered by a
tachometergenerator. A twostage
250C20R/2 turboshaft engine man-
power turbine drives the helicopter
ufactured by the Allison Engine
rotor system, governor control and N2
Company Inc.
tachometergenerator. A start counter
(3). The engine is secured in the helicopter is standard and part of the engine
by three mount assemblies and ac- ignition system
cessed through two hinged, airsealed
doors. (2). Allison Engine Operation and Mainte-
nance Manuals are the primary
(4). A beltdriven blower provides external information source for engine fault
cooling air through strategically isolation and maintenance data (Ref.
positioned ducts that direct air onto Sec. 010000). Refer to these manuals
engine exterior surfaces and through for specific engine maintenance proce-
the engine and transmission oil cooler dures.
heat exchangers. Spent blower air is
exhausted aft through an annular (3). Starter operational limitations are in
opening between the engine exhaust the applicable Pilots Flight Manual.
pipes and fuselage.
3. Models 250C20B and 250C20R/2 Power
(5). Engine intake air may be filtered Plant Fault Isolation
through a standard screen or optional
air particle separator/mist eliminator (Ref. Table 1)
assembly. Intake air is drawn through a
plenum chamber and into the engine (1). Check engine support systems, i.e.; chip
intake bellmouth by the compressor. detectors, instruments, fuel supply,
Engine compartment air is separated electrical systems, etc., to ensure that
from compressor intake air by a seal helicopter equipment is functioning
ring. correctly before disassembling engine
systems for an indicated fault.
2. Power Plant Operation
(2). Inspect and isolate engine problems per
(1). Allison turboshaft engines installed in the applicable Allison Engine Operation
369D/E 500N model helicopters and Maintenance Manual.
Table 1. Power Plant Fault Isolation

High frequency vibration (1) Loose engine mount bolts. Retorque engine mount bolts to 100
140 inchpounds (11.30 15.82
Nm).
NOTES:
(1) High frequency vibrations may be caused by other drive and rotor system components.
Page 1/(2 blank)

710000 Revision 22
MAINTENANCE MANUAL
POWER PLANT
1. Engine Removal (e). Disconnect ground jumper at center
firewall stud.
A. Engine Disconnecting for Removal
(f). Unclamp and remove electrical
harness from right engine mount
After each opening, removal (369D only).
WARNING or replacement of any part
of the engine and/or aircraft fuel sys- (5). Remove combustion chamber drain line
tem between the aircraft fuel tank and from burner drain valve.
the engine fuel nozzle, the fuel system
(6). Disconnect fuel inlet line from engine.
must be bled to remove trapped air.
Failure to comply with this procedure (7). Disconnect fuel pump seal drain line.
can result in engine flameout or power
loss. (8). Disconnect compressor cabin air bleed
Cap fluid lines and fittings with outlet tube from tee fitting on engine
CAUTION approved devices. Do not use compressor scroll.
tape to cover fuel and oil openings. Tape (9). Loosen compressor cooling air ducts at
adhesives loosened by fuel or oil can con- firewall coupling and engine oil cooler
taminate systems. deflector coupling (Ref. Sec. 716000).
(1). Set all switches OFF. Disconnect
external power. Disconnect battery. (10). Disconnect duct support bracket at
hoisting eye. Remove ducts from engine
NOTE: Tag all hardware, wire terminals, fuel compartment (Ref. Figure 401, view B).
and oil lines before removal to expedite en-
gine installation. Identify and bag loose (11). Disconnect torquemeter oil line from
parts to prevent loss or damage. firewall.
(2). Remove main transmission drive shaft (12). Disconnect oil pressure indicator line
(Ref. Sec. 631000). from firewall.
(3). Remove engine exhaust pipes (Ref. Sec. (13). Disconnect N2 control rod from idler
782000). Cover engine exhaust bellcrank. Secure control rod to fire-
outlet. wall.
(4). Disconnect electrical wiring from (14). Disconnect antiicing system as follows:
engine;
(a). Model 250C20B;
(a). Disconnect engine electrical harness
Disconnect antiice control valve
ground lead and plug from recep-
lever (Ref. Figure 401, view A).
tacle.
(b). Disconnect thermocouple wire leads (b). Model 250C20R/2:
from terminal studs on engine Remove electrical connector from
compartment door frame (Ref. antiice solenoid valve. Unclamp and
Figure 401, view C). remove wiring harness from horizon-
tal firewall shield.
(c). Remove thermocouple lead clamps
from door frame and exhaust pipe (15). Disconnect N1 control rod from gas
clamp. producer lever. Secure control rod to
firewall.
(d). Disconnect terminals E, C, and B
from startergenerator. (16). Disconnect accessory drive vent tube.
Page 401
710000 Revision 22
MAINTENANCE MANUAL
CONTROL CABLE
CLEVIS CONTROL VALVE
LEVEL
SCREW (5 PLCS)
(NOTE 1)
AIR INLET BELL
NUT (5 PLCS)
(NOTE 1)
ENGINE HOIST
NO. 1 BEARING
OIL RETURN
LINE
EXHAUST DUCT
ANTIICING VALVE
INSTALLATION
(NOTE 2)
CABIN AIR
THERMOCOUPLE LEAD
OUTLET TUBE
MOUNT FITTING
P307
(NOTE 3)
DRIVESHAFT
TORQUEMETER
OIL LINE
GROUND JUMPER
N2 CONTROL ROD
AIRFRAME HOIST
FITTING
FUEL CONTROL
FUEL PUMP SEAL DRAIN LINE
DRAIN LINE
FUEL SUPPLY HOSE
BRACKET COMBUSTION CHAMBER
DRAIN LINE
ROTATED
NOTES:
COMPRESSOR CASE 1. C20R/2 ENGINE (6 PLCS)
COOLING AIR DUCT TURBINE CASE 2. C20B ENGINES ONLY.
COOLING AIR DUCT 3. C20R/2 ENGINES ONLY.
G7100001
Figure 401. Allison 250C20B and 250C20R/2 Engine Removal and Installation (Sheet 1 of 2)
Page 402
Revision 22 710000
MAINTENANCE MANUAL
THERMOCOUPLE
LEAD STUD
THERMOCOUPLE
LEAD
ENGINE DOOR
FRAME
THERMOCOUPLE LEAD INSTALLATION
OIL PRESSURE LINE
MOUNT ADJUSTER OIL RETURN LINE AIR INLET

OIL SUPPLY LINE BELL
HARNESS
CLAMP
RH MOUNT FITTING
ELECTRICAL
HARNESS
GROUND THERMOCOUPLE
LEAD LEAD
OIL VENT LINE
PLUG
LOWER MOUNT FITTING
ACCESSORIES
DRIVE VENT
TUBE FUEL CONTROL DRAIN
N1 CONTROL ROD
GENERATOR TERMINALS
G7100002
Figure 401. Model 250C20B and 250C20R/2 Engine Removal and Installation (Sheet 2 of 2)
Page 403
710000 Revision 22
MAINTENANCE MANUAL
(17). Disconnect fuel control drain line. Do not use fuel or oil lines as
CAUTION hand holds. Do not allow engine
The oil cooler is fragile. Unless to strike airframe while maneuvering it out
CAUTION otherwise required, disconnect of the helicopter.
oil supply and return lines only at engine.
(5). Align engine stand (ST401) under
Support oil cooler port boss with a backup
engine with adjustable support shaft on
wrench when oil line removal is required.
left side (Ref. Figure 402).
Do not strain or bend unsupported tubes.
(6). Slowly lower engine out of helicopter.
(18). Disconnect and cap engine oil inlet, Align engine side mount fittings
outlet and vent lines. between fixed and adjustable support
shafts.
B. Removal of Disconnected Engine
(7). Screw in adjustable support shaft until
engine mount fittings are securely
(Ref. Figure 401 and Figure 402) engaged with support shaft sockets.
(8). Insert detent pin through adjustable
Special Tools support shaft.
Item Nomenclature (9). Remove hoist from engine lift fitting.
ST401 Engine stand (10). If engine is to be stored or transported,
ST402 Engine hoist secure upper end of engine stand
transport and storage bar to engine
lifting eye fitting.
CAUTION 2. Engine Installation
D Do not remove engine mounts or disturb A. Engine Installation in Mounts

engine mount adjustments to remove the (Ref. Figure 401 and Figure 402)
engine (Ref. CSPSRM6).
D Enginetransmission alignment must be Consumable Materials
inspected and realigned whenever one or (Ref. Section 910000)
more engine mount assemblies is re- Item Nomenclature
placed or the existing enginetransmis-
CM702 Lockwire CRES
sion alignment adjustment is disturbed.
Do not disturb adjustable engine mount
fittings unless an enginetransmission Special Tools
alignment check is planned. (Ref. Section 910000)
Item Nomenclature
(1). Install engine hoist apparatus (ST402) ST402 Engine hoist
between airframe hoist fitting and
engine hoist eye. (1). Open engine access doors.
(2). Have an assistant apply tension to (2). Position engine to line up engine lifting
engine with hoist. eye under airframe lift fitting.
(3). Remove detent pin from adjustable
(3). Maintain downward pressure on rear of
support shaft on engine stand. Detach
engine during mount bolt removal.
transport and storage bar from engine
Unbolt lower engine mount assembly
lift fitting.
from engine fitting.
(4). Install engine hoist (ST402) between
(4). Unbolt left and right engine mount airframe fitting and engine hoist
assemblies from engine fittings. fitting.
Page 404
Revision 22 710000
MAINTENANCE MANUAL
(5). Have an assistant tension hoist to Proper tightening of engine

support engine. Unscrew engine stand WARNING tubing connections is criti-
adjustable support shaft. cal to flight safety. Correct torque val-
ues must be used at all times. Excessive
(6). Move engine to disengage fixed shaft. torque on fuel or pneumatic sensing
Roll stand away from engine. system connections can result in crack-
ing of the flare causing an air leak
which can cause flameout, power loss,
CAUTION or overspeed.
(1). Connect torquemeter oil line to
D Do not use tubes or hoses as hand holds. firewall.
Do not allow engine to strike airframe.
Avoid damaging engine intake bell. (2). Connect oil pressure gauge line to
D Prevent FOD, ensure that no foreign ob- firewall.
jects are trapped in firewall seal ring. (3). Connect engine oil vent line. Torque
line nut to 120 140 inchpounds
(7). Have hoist operator raise engine while (13.56 15.82 Nm) (Ref. Figure 401).
while pushing down to maintain correct
helicopter and engine alignment. Do not bend oil return line.
CAUTION Bending loads are transferred to
oil cooler port and may fracture cooler.
(8). Align left and right engine mount
assemblies with engine mount fittings (4). Connect engine oil inlet and outlet
and install bolts and washers (Ref. lines. Handtighten until snug.
Figure 403). Torque bolts to 100 140 Wrenchtighten approximately 1/4 turn
inchpounds (11.30 15.82 Nm). or until definite resistance is felt.
Safety bolts to engine mounts using
lockwire (CM702). (5). Position accessory drive vent elbow and
connect with vent tube. Torque elbow
(9). Align hole in lower engine mount jamnut to 150 250 inchpounds
assembly with engine mount fitting and (16.95 28.25 Nm). Torque tube nut to
install bolt and washer. Torque bolt to 20 30 inchpounds (2.26 3.39 Nm)
100 140 inchpounds (11.30 15.82 (Ref. Figure 402, detail B).
Nm). Safety bolt to engine mount using (6). Connect Nl control rod to lever with
lockwire (CM702). bolt, two washers and nut. Install bolt
with head outboard, one standard OD
(10). Ensure engine air inlet firewall seal washer under nut and one large 0.80
ring contacts firewall seal around its inch (20.32 mm) diameter washer
entire circumference. under bolt head. Torque nut to 40 45
inchpounds (4.52 5.08 Nm). Install
(11). Remove hoist from helicopter. a new cotter pin.
(7). Connect short N2 control rod to gover-
B. Connecting an Installed Engine nor lever with bolt head up, one
standard OD washer under head and
(Ref. Figure 401 and Figure 402) one large 0.80 inch (20.32 mm) OD
washer under nut. Install a new cotter
pin. Connect long N2 control rod with
Consumable Materials bolt head forward, two washers and
(Ref. Section 910000) nut. Install a new cotter pin.
Item Nomenclature
(8). Connect engine fuel pump seal drain
CM702 Lockwire CRES line. Torque tube nut to 20 30 inch
pounds (2.26 3.39 Nm).
Page 405
710000 Revision 22
MAINTENANCE MANUAL
ENGINE MOUNT
FITTING SCREW (5 PLCS) ENGINE AIR
(NOTE 2) INLET BELL VENT ELBOW
ANGLE
(NOTE 1) WASHER
(NOTE 2) ORING
JAM NUT
GROUND JUMPER WASHER VENT ELBOW INSTALLATION

(NOTE 1) (NOTE 2) ACCESSORY DRIVE
ENGINE MOUNT FITTING

INSTALLATION (TYP)
N2 TACHOMETER
GENERATOR
NUT (5 PLCS)
(NOTE 2)
N1 TACHOMETER
GENERATOR
OIL INLET COUPLING IGNITION EXCITER

LEAD
OIL OUTLET COUPLING
START COUNTER
KNIFE SPLICE
CHIP DETECTOR
ELECTRICAL CONNECTORS
HARNESS
FUEL INLET REDUCER
FUEL FILTER SWITCH

KNIFE SPLICE
"D" WIRE LEAD
STARTERGENERATOR
REDUCER "A" WIRE LEAD
ORING
OIL PRESSURE
SNUBBER ENGINE STAND
ORING
NOTES:
OIL PRESSURE REDUCER 1. APPLIES ONLY TO LOWER MOUNT.
FITTING INSTALLATION 2. C20R/2 ENGINES (6 PLCS).
3. C20B ENGINES ONLY.
4. REMOVE CLUTCH ASSEMBLY WITH SEAL, COUPLING
AND ASSOCIATED HARDWARE INTACT.
G7100011B
Figure 402. Model 250C20B and 250C20R/2 Engine Stripping and Buildup (Sheet 1 of 2)
Page 406
Revision 30 710000
MAINTENANCE MANUAL
HOSE FUEL PUMP SEAL ELBOW NUT AND ORING

AIR INLET BEFORE FILTER PORT (BF)
BELL FIREWALL SEAL RING ORING
REDUCER
SPECIAL TEE FITTING
SCREW
JAM NUT (5 PLCS)
ORING NUT
ORING AFTER FILTER
(5 PLCS) PORT (AF)
CABIN AIR FITTING ANTIICE VALVE
INSTALLATION (NOTE 3) FITTING
PRESSURE SWITCH
BUSHING
FIREWALL SEAL
HOSE ASSEMBLY
OVERRUNNING
CLUTCH FUEL PRESSURE SWITCH
(NOTE 4) INSTALLATION
SPARK IGNITER
LEAD
HOSE
FUEL CONTROL
DRAIN UNION
DETENT PIN
3/8 IN. (9.525 MM)
DIA. BOLT
LIFT FITTING
5/16 IN. (7.9375 MM)
DIA. BOLT (2)
ENGINE LIFT FITTING
INSTALLATION
GOVERNOR CONTROL IDLER

SUPPORT, BELLCRANK AND
N2 CONTROL ROD ASSEMBLY
REDUCER
ORING
SNUBBER
ACCUMULATOR ORING
TORQUE OIL PRESSURE FITTING

INSTALLATION
G71000012
Figure 402. Model 250C20B and 250C20R/2 Engine Stripping and Buildup (Sheet 2 of 2)
Page 407
710000 Revision 22
MAINTENANCE MANUAL
(9). Connect fuel inlet line to fuel pump. located on right upper engine door
Torque hose nut to 230 260 inch frame with chromel and alumel nuts.
pounds (25.99 29.38 Nm).
(17). Install main transmission drive shaft
NOTE: Ensure burner drain valve and plug are (Ref. Sec. 631000).
installed in combustion chamber with an O (18). Remove all identifying tags from wires
ring on each part. Ensure drain valve is in and hardware.
the aft (lowest) position.
Misrigging of throttle controls
(10). Install combustion chamber drain line CAUTION can cause inadvertent flameout
on drain valve. when throttle is rapidly closed to the idle po-
sition.
(11). Connect fuel control drain line. Torque
drain line nut to 20 30 inchpounds (19). Rig gas producer (N1) and power
(2.26 3.39 Nm) (Ref. Figure 401). turbine (N2) controls (Ref. Chap. 76).
(12). Connect antiice system as follows: After each opening, removal
(a). Model 250C20B: of the engine and/or aircraft fuel sys-
Connect antiicing control cable to tem between the aircraft fuel tank and
antiicing control valve lever with the engine fuel nozzle, the fuel system
clevis pin and washer. Secure with must be bled to remove trapped air.
cotter pin (Ref. Figure 401, detail A). Failure to comply with this procedure
can result in engine flameout or power
(b). Model 250C20R/2: loss.
Install connector P307 to antiice
solenoid valve and secure antiicing (20). Perform fuel system bleed.
wiring harness with clamps.
(21). Perform an engine deceleration check
(13). Install cooling air ducts and air duct per the Pilots Flight Manual.
support bracket on hoisting eye above
NOTE: Make engine adjustments per the Alli-
engine. Connect and tighten ducts on
son Engine Operation and Maintenance
firewall coupling and oil cooler deflec-
Manual.
tor.
(22). Perform an antiicing system opera-
(14). Secure engine electrical harness to tional check (Ref. Sec. 751000).
engine mount with cushioned loop
clamp. Connect harness plug to recep- (23). Inspect engine installation and connec-
tacle and safety with lockwire (CM702). tions for proper routing and security.
(a). Install engine harness ground lead. 3. Engine Stripping
(b). Install E, C, and B generator leads on (Ref. Figure 402)

startergenerator terminal block
with washers and nuts. Special Tools
(c). At lower engine mount fitting; install Item Nomenclature
bonding jumper on engine compart-
ment firewall stud. Torque bolt to 100 ST401 Engine stand
140 inchpounds (11.30 15.82 ST402 Engine hoist
Nm). Safety bolt to engine mount
using lockwire (CM702). (1). Install engine in engine stand (ST401).
(15). Install engine exhaust pipes and (2). Disconnect wire leads from generator A
thermocouple clamp support. and D terminals.
(16). Attach thermocouple clamps in frame (a). Loosen mounting clamp and remove
and leads to terminal block studs startergenerator.
Page 408
Revision 22 710000
MAINTENANCE MANUAL
(b). Remove mounting flange and gasket. (a). Remove hose, reducer and Oring
from before filter (BF) port (Ref.
(c). Install cover on generator mounting Figure 402, view D).
pad.
(b). Remove bushing, fuel pressure
(3). Disconnect electrical connectors from:
switch, fitting and Orings from after
(a). Chip detectors. filter (AF) port.
(b). Tachometer generators. (12). Remove engine air inlet bell and
firewall seal.
(c). Ignition exciter.
(13). Model 250C20B Only:
(d). Start counter.
Remove antiicing valve lever assembly
(e). Fuel filter pressure switch. from poppet guide (Ref. Figure 401,
view A).
(f). Unclamp and remove electrical
harness from overrunning clutch and (14). Remove fuel pump seal drain port
lower engine mount fitting. elbow and jamnut.
(g). Remove entire engine electrical (15). Remove governor control idler support,
harness. bellcrank and short N2 control rod as
an assembly. Install vacuum/hydraulic
NOTE: Discard all used Oring packings.
pump pad cover.
(4). Remove fuel supply and return reduc-
ers/unions. (16). Remove overrunning clutch and
firewall seal. Install cover on engine
(5). Remove oil supply and return reducers/ pad.
unions.
(17). Remove fuel control drain fitting.
(6). Remove accessories drive vent elbow
and jamnut. (18). Remove pneumatic line accumulator
per Allison installation bulletin (Ref.
(7). Remove compressor bleed air hose, tee Sec. 010000).
and jamnut (Ref. Figure 402. view C).
(19). Hoist (ST402) engine out of engine
(8). Remove oil pressure reducer/snubber.
stand.
(9). Remove torquemeter reducer/snubber.
(20). Unbolt and remove engine mount
(10). Remove N1 and N2 tachometer genera- fittings.
tors and gaskets.
(21). Install engine in shipping container.
(11). Remove fuel pressure switch installa-
tion as follows: (22). Remove engine hoist fitting.
Page 409
710000 Revision 22
MAINTENANCE MANUAL
ENGINE HOIST
FITTING
BULKHEAD SPLICE
FITTING
FIREWALL BULKHEAD
STA 124.00
BULKHEAD SPLICE
FITTING
LOWER ENGINE
MOUNT
LOWER ENGINE
MOUNT ATTACH
FITTING
LOWER ENGINE MOUNT INSTALLATION
ENGINE
FITTING
UPPER ENGINE
MOUNT ASSY
AIRFRAME
FITTING
LANDING GEAR
DAMPER FITTING
UPPER ENGINE MOUNT INSTALLATION
NOTE:
THICK WASHERS ARE USED IN LOCATIONS
MARKED WITH ASTERISK ( * ).
G710002
Figure 403. Model 250C20B and 250C20R/2 Engine Mounts and Airframe Fittings
Page 410
Revision 22 710000
MAINTENANCE MANUAL
4. Engine Buildup (3). Hoist engine clear of shipping contain-

er.
(4). Inspect engine as follows:
Proper tightening of engine
WARNING tubing connections is criti- (a). If shipping container moisture
cal to flight safety. Correct torque val- indicator was other than a light blue
ues must be used at all times. Excessive color, examine engine for corrosion.
torque on fuel or pneumatic sensing Perform corrosion corrective mainte-
system connections can result in crack- nance per Allison Operation and
ing of the flare causing an air leak Maintenance Manual as required.
which can cause flameout, power loss,
(b). Inspect inlet guide vanes for damage.
or overspeed.
(c). Exhaust and inlet openings for FOD.
Consumable Materials (d). Turbine blades for damage.
Item Nomenclature (e). Install covers over intake and
CM113 Antiseize compound low temperature exhaust ports.
CM114 Petrolatum (f). All fasteners for security, slippage
CM118 Grease marks for alignment, potting com-
CM502 Sleeving, fiberglass pound and, or correctly installed
CM702 Lockwire CRES lockwire where applicable.
CM808 Lacing cord (g). Tubes and hoses for damage.
Special Tools
(5). Record engine serial number and
startcounter reading in appropriate
Item Nomenclature
log.
ST401 Engine stand Prevent damage to machined
CAUTION surfaces and contamination. Re-
move covers from engine one at a time as re-
(1). Review Allison instructions for remov- quired by the installation sequence.
ing engine from shipping container in
Allison Operation and Maintenance (6). Install lower engine mount fitting with
Manual. angle and ground wire under aft bolt
head. Install side engine mount fittings,
Prevent FOD Inspect and clean bolts and washers. Torque bolts to 140
CAUTION all accessories and hardware 160 inchpounds (15.82 18.08 Nm).
prior to installing parts on engine. Install lockwire (CM702).
NOTE: Replace Orings and gaskets with new (7). Install engine in engine stand (ST401).
parts. Lubricate fuel line packings with
clean jet fuel or petrolatum (CM114) prior to (8). Install accumulator in pneumatic line
installation. Lubricate oil line packings with per Allison installation bulletin (Ref.
clean engine oil prior to installation. Apply a Sec. 010000).
thin coating of antiseize compound (9). Install fuel control drain fitting and
(CM113) to the male threads of unions and Oring.
fittings before torquing.
(10). Remove overrunning clutch pad cover.
(2). Install engine hoist lift fitting and bolts. Install overrunning clutch, firewall seal
Torque 3/8 inchdiameter bolt to 160 and engine electrical harness angle and
190 inchpounds (18.08 21.47 Nm). clamp (Ref. Sec. 631000).
Torque 5/16 inchdiameter bolts to 140
160 inchpounds (15.82 18.08 (11). Install oil pressure gauge reducer/snub-
Nm). ber and Oring.
Page 411
710000 Revision 22
MAINTENANCE MANUAL
(12). Install torquemeter reducer/snubber (c). Install reducer and Oring in BF

and Oring. port.
Engine spark igniter wire lead (d). Install hose assembly between AF
CAUTION may obstruct governor arm on a and BF fittings.
new or overhauled engine. (20). Lubricate splines with grease (CM118)
and install N1 and N2 tachometer
(13). Reroute engine spark igniter lead below generators. Install washers and nuts.
governor as shown (Ref. Figure 402). Torque nuts to 70 90 inchpounds
Support igniter lead only with cush- (7.91 10.17 Nm).
ioned clamps and existing fasteners.
Replace and, or add clamps as required. (21). Install special tee, jamnut and Oring
in compressor scroll bleed air port. Do
(14). Remove vacuum/hydraulic pump pad not torque at this time.
cover from gear case.
(22). Install hose between special tee and
(15). Install governor control idler support, compressor bleed air elbow. Torque tee
bellcrank and short N2 control rod as jamnut. Torque hose nuts to 150 250
an assembly. Do not connect control rod inchpounds (16.95 28.25 Nm).
to governor lever.
(23). Install accessory gear case vent elbow,
Only high temperature all met- jamnut and Oring. Do not torque at
CAUTION al self locking nuts shall be used this time.
to fasten governor control idler support (24). Install oil inlet and outlet couplings and
bracket to engine accessory pad. Orings.
(16). Install elbow with Oring and jamnut (25). Install fuel inlet reducer and Oring.
in fuel pump seal drain port.
(26). Install starter/generator.
(17). Model 250C20B Only: Always support the weight of
Install antiicing valve lever with CAUTION the starter/generator during re-
attaching hardware on poppet guide. moval/installation. Damage can occur if
Position poppet guide so that lever is weight is supported by the shear shaft.
parallel with top of engine.
(a). Remove starter/generator pad cover.
(18). Install engine air inlet bell and firewall Install starter/generator mount with
seal. gasket, washers and nuts. Torque
nuts to 100 140 inchpounds
(19). Install fuel pressure switch fitting and (11.29 15.81 Nm).
Oring in fuel pump AF port (Ref. Sec.
280000). (b). Install starter/generator with V
clamp. Torque clamp nut to 50
Ensure both halves of the fuel inchpounds (5.64 Nm).
CAUTION filter pressure switch are
gripped by wrench when torquing the in- (c). Tap around clamp with a rawhide
stallation. An asymmetrical wrench grip mallet to seat clamp on flange.
may cause shearing motion between assem- Retorque clamp nut to 50 inch
bly halves. Such damage may result in leak- pounds (5.64 Nm).
age or failure to operate FUEL FILTER (d). Continue tapping around clamp and
caution/warning light, or both. retorquing clamp nut until nut no
longer turns when specified torque is
(a). Install fuel filter pressure switch and applied.
Oring.
(27). Clamp engine electrical harness to
(b). Install bushing and Oring on lower engine mount and startergener-
switch. ator.
Page 412
Revision 26 710000
MAINTENANCE MANUAL
(28). Connect ignition exciter wire lead and (1). Disconnect accessory drive overboard
startergenerator A and D wire leads. vent tube from elbow on engine accesso-
ry case; remove vent tube from helicop-
(29). Attach electrical connectors to both chip ter.
detectors and safety with lockwire
(CM702).
(2). Install extension tube to existing vent
(30). Connect N1 and N2 tachometer genera- tube as follows:
tors connectors.
(31). Connect start counter lead and fuel (a). Position extension tube over vent
pressure switch wire lead splices. tube. Drill rivet holes in line thru
Install fiberglass sleeving (CM502) over tubing.
splices and secure with high tempera-
ture lacing cord (CM808). (b). Apply sealant (CM425) between
tubes. Install two NAS1738B42
5. Modification of Accessory Drive Gearbox
rivets. Fillet seal around circumfer-
Overboard Vent Tube (SN 0004D 0519D)
ence of tubes.
(Ref. Figure 404) The following procedure adds
a four inch extension tube to the existing (3). Remove existing grommet at lower
engine accessory drive gearbox vent tube to fuselage Sta. 127.00 and install new
reduce oil spattering onto the lower fuselage. MS3548922 grommet.
Consumable Materials (4). Insert extension tube thru grommet

(Ref. Section 910000) and connect vent tube to elbow on
Item Nomenclature engine accessory case. Torque line nut
CM425 Sealing compound to 120 140 inchpounds (13.56
15.82 Nm).
FUSELAGE SKIN
STA. 127.00
NAS1738B42 RIVET
(2 REQD.) MS3548922 GROMMET
NOTE
369A8010615
TUBE ASSY. EXTENSION TUBE
0.250 IN.
(6.35 MM)
0.84 IN.
(21.34 MM)
NOTE: SEAL BETWEEN TUBES

BEFORE ASSEMBLY AND FILLET 4.85 IN.
(12.319 CM)
SEAL ABOUT CIRCUMFERENCE.
88295A
Figure 404. Extension of Engine Accessory Drive Overboard Vent Tube

710000 Revision 26
MAINTENANCE MANUAL
Section
710030
Power Plant
(250C30)
MAINTENANCE MANUAL
POWER PLANT
1. Power Plant Description sor, N1 tachometergenerator and
accessory gear train, and a twostage
(1). MDHI 369FF helicopter is powered by a power turbine driving the spare
250C30 turboshaft engine manufac- accessory pad, governor, N2 tachome-
tured by the Allison Engine Company tergenerator and helicopter rotor
Inc. system. An overrunning clutch, drive
(2). The engine is secured in the helicopter shaft, starter generator, fuel, oil, drain
by three mount assemblies and ac- and bleed air lines, exhaust ducting,
cessed through two hinged, airsealed mounting and hoist fittings and control
doors. levers adapt the engine to the helicop-
ter.
(3). A beltdriven blower forces external
cooling air through strategically (2). Allison Engine Operation and Mainte-
positioned ducts that direct the air onto nance Manuals are the primary
engine exterior surfaces and through information source for engine fault
the engine and transmission oil cooler isolation and maintenance data (Ref.
heat exchangers. Spent cooling air is Sec. 010000). Refer to these manuals
exhausted aft through an annular for specific engine maintenance proce-
opening between the engine exhaust dures.
duct and fuselage.
(3). Starter operational limitations are in
(4). Engine intake air may be filtered the applicable Pilots Flight Manual.
through a standard screen or optional
air particle separator/mist eliminator 3. Model 250C30 Power Plant Fault
assembly. Intake air is drawn through a Isolation
plenum chamber and into the engine
intake bellmouth by the compressor. (Ref. Table 1)
Engine compartment air is separated
from compressor intake air by a seal (1). Check engine support systems, i.e.; chip
ring. detectors, instruments, fuel supply,
electrical systems, etc., to ensure that
2. Power Plant Operation helicopter equipment is functioning
correctly before disassembling engine
(1). The Allison 250C30 turboshaft engine systems for an indicated fault.
consists of a single stage centrifugal
flow compressor, a canannular (2). Inspect and isolate engine problems per
combustion chamber, a twostage gas the applicable Allison Engine Operation
producer turbine driving the compres- and Maintenance Manual.

Symptom Probable trouble Corrective action
High frequency vibration (1) Loose engine mount bolts Retorque engine mount bolts to 100
140 inchpounds (11.30 15.82
Nm).
NOTES:
Page 1/(2 blank)

710030 Revision 22
MAINTENANCE MANUAL
POWER PLANT
1. Engine Removal (7). Loosen and remove remaining engine
cooling air ducts from engine compart-
A. Engine Disconnecting for Removal ment (Ref. Figure 402, views A and D).
(Ref. Figure 401 and Figure 402) (8). Remove combustion chamber drain line
After each opening, removal from burner drain valve.
WARNING or replacement of any part (9). Disconnect fuel inlet line at engine
of the engine and/or aircraft fuel sys- mounted fuel pump and cap line.
tem between the aircraft fuel tank and
the engine fuel nozzle, the fuel system (10). Disconnect and remove fuel pump seal
must be bled to remove trapped air. drain line.
Failure to comply with this procedure
can result in engine flameout or power (11). Disconnect and remove fireshield drain
loss. line.
Cap fluid lines and fittings with (12). Disconnect fuel control vent line and
CAUTION approved devices. Do not use cap line.
tape to cover fuel and oil openings. Tape (13). Disconnect customer bleed line at
adhesives loosened by fuel or oil can con- firewall.
taminate systems.
(14). Disconnect torquemeter oil line from
(1). Set all switches OFF. Disconnect firewall.
external power. Disconnect battery.
(15). Disconnect oil pressure indicator line
NOTE: Tag all hardware, wire terminals, fuel from firewall.
and oil lines before removal to expedite in-
stallation. Identify and bag loose parts to (16). Disconnect N2 control rod from idler
prevent loss or damage. bellcrank. Secure control rod to fire-
wall.
(2). Remove main transmission drive shaft
(Ref. Sec. 631000). (17). Disconnect N1 control rod from gas
producer lever. Secure control rod to
(3). Remove engine exhaust duct (Ref. Sec. firewall.
783000). Cover engine exhaust
outlet. (18). Disconnect and remove startergenera-
tor cooling air duct from starter and
(4). On left engine compartment door fuselage bracket.
frame; unclamp and disconnect thermo-
couple wire leads from terminal studs The oil cooler is fragile. Unless
CAUTION otherwise required, disconnect
(Ref. Figure 401, view B).
oil supply and return lines only at engine.
(5). Unplug engineairframe electrical Support oil cooler port boss with a backup
harness connector from engine recep- wrench when oil line removal is required.
tacle. Do not strain or bend unsupported tubes.
(6). Disconnect thermal switch plug from (19). Disconnect and cap engine oil inlet,
firewall. outlet and vent lines.
Page 401
710030 Revision 22
MAINTENANCE MANUAL
COMBUSTION
CHAMBER DRAIN LINE
STARTERGENERATOR
COOLING DUCT
LONG RANGE FUEL FUEL PUMP

TANK LINE INLET
ENGINE GEARCASE
COOLING DUCT UPPER ENGINE MOUNT
LH SIDE SHOWN
RH SIDE OPPOSITE GENERATOR
TERMINALS
UPPER ENGINE N1 CONTROL ROD (E, C, B ONLY)
MOUNT FITTING
THERMOCOUPLE
LEAD STUD (2)
ENGINE MOUNTING
PAD ASSY
THERMOCOUPLE LEAD
UPPER ENGINE MOUNT ENGINE DOOR

FRAME
THERMOCOUPLE LEAD INSTALLATION

LANDING GEAR
DAMPER FITTING
G7100031
Figure 401. Model 250C30 Engine Removal and Installation (Sheet 1 of 2)
Page 402
Revision 22 710030
MAINTENANCE MANUAL
LOWER ENGINE MOUNT

INSTALLATION
HOISTING EYE
FITTING
BRACKET
LOWER ENGINE CLAMP

MOUNT
FIRESHIELD DRAIN
TUBE ASSY
POWER TURBINE COOLING
FUEL PUMP SEAL DUCT INSTALLATION
LOWER ENGINE DRAIN TUBE ASSY
MOUNT FITTING
ENGINE AIR
INLET BELL
ENGINE OIL
INLET LINE
BLEED DUCT
ENGINE OIL
OUTLET LINE
MAIN TRANSMISSION
DRIVESHAFT
TORQUEMETER
OIL PRESSURE
N2 CONTROL ROD
ENGINE MOUNTING
ENGINE HARNESS PAD ASSY
DISCONNECT
G7100032
Figure 401. Model 250C30 Engine Removal and Installation (Sheet 2 of 2)
Page 403
710030 Revision 22
MAINTENANCE MANUAL
B. Removal of Disconnected Engine between fixed and adjustable support

shafts.
(7). Screw in adjustable support shaft until
engine mount fittings are securely
Special Tools engaged with support shaft sockets.
Item Nomenclature (8). Insert detent pin through adjustable
support shaft.
ST401 Engine stand
ST402 Engine hoist (9). Remove hoist from engine lift fitting.
(10). If engine is to be stored or transported,

secure upper end of engine stand
CAUTION transport and storage bar to engine
lifting eye fitting.
D Do not remove engine mounts or disturb
engine mount adjustments to remove en-
gine. 2. Engine Installation
D Enginetransmission alignment shall be A. Engine Installation in Mounts

inspected whenever one or more engine
mount assemblies is replaced or the exist- (Ref. Figure 401 and Figure 402)
ing alignment is disturbed. Do not disturb
adjustable engine mount fittings unless
an enginetransmission alignment check
is planned.
Item Nomenclature
(1). Install engine hoist apparatus (ST402) CM702 Lockwire CRES

between engine hoist eye and airframe
hoist fitting. Special Tools
(2). Have an assistant apply tension to Item Nomenclature
engine with hoist. ST402 Engine hoist
(3). Maintain downward pressure on rear of

engine during mount bolt removal. (1). Open engine access doors.
Unbolt engine at lower engine mount
fitting. Take care not to damage rod end (2). Position engine to line up engine lifting
bearings. eye under airframe lift fitting.
(4). Unbolt left and right engine mount (3). Remove detent pin from adjustable
assemblies from engine fittings. support shaft on engine stand. Detach
lift fitting.
Do not use fuel or oil lines as
CAUTION hand holds. Do not allow engine (4). Install engine hoist (ST402) between
to strike airframe while maneuvering it out airframe fitting and engine hoist
of the helicopter. fitting.
(5). Align engine stand (ST401) under (5). Have an assistant tension hoist to
engine with adjustable support shaft on support engine. Unscrew engine stand
left side. adjustable support shaft.
(6). Slowly lower engine out of helicopter. (6). Move engine to disengage fixed shaft.
Align engine side mount fittings Roll stand away from engine.
Page 404
Revision 22 710030
MAINTENANCE MANUAL
(2). Connect oil pressure gauge line to

CAUTION firewall.
D Do not use tubes or hoses as hand holds.
(3). Connect engine oil vent line. Torque
Do not allow engine to strike airframe or
line nut to 120 140 inchpounds
components. Avoid damaging engine in-
(13.56 15.82 Nm).
take bell.
D Prevent FOD ensure that no foreign ob- Do not bend oil return line.
jects are trapped in firewall seal ring. CAUTION Bending loads are transferred to
(7). Have hoist operator slowly raise engine
while pushing engine down to maintain (4). Connect engine oil outlet and inlet
correct engine and transmission lines. Handtighten until snug.
alignment. Wrenchtighten approximately 1/4 turn
or until definite resistance is felt.
(8). Align left and right engine mount
assemblies with engine fittings. Install (5). Position accessory drive vent elbow and
bolts and washers (Ref. Figure 403). connect with vent tube. Torque elbow
Torque bolts to 220 360 inchpounds jamnut to 150 250 inchpounds
(24.86 40.67 Nm); Safety bolts to (16.95 28.25 Nm). Torque tube nut to
engine mounts using lockwire (CM702). 20 30 inchpounds (2.26 3.39
Nm).
(9). Align hole in lower engine mount
assembly with engine fitting. Install (6). Connect N1 control rod to lever with
bolt, washers and nut. Torque nut to 95 bolt, two washers and nut. Install bolt
110 inchpounds (10.73 12.43 with head outboard, one standard OD
Nm); install cotter pin as required. washer under nut and one large 0.8
inch diameter washer under head.
(10). Ensure engine air inlet firewall seal Torque nut to 40 45 inchpounds
ring contacts firewall seal around its (4.52 5.08 Nm). Install a new cotter
entire circumference. pin.
(11). Remove hoist from helicopter.
(7). Connect short N2 control rod to gover-
B. Connecting an Installed Engine nor lever with bolt head up, one
standard OD washer under head, one
(Ref. Figure 401 and Figure 402) large 0.80 inch (20.32 mm) OD washer
under nut and a new cotter pin.
Connect long N2 control rod with bolt
Consumable Materials head forward, two washers, nut and a
(Ref. Section 910000) new cotter pin.
Item Nomenclature
CM702 Lockwire CRES (8). Connect engine fuel pump seal drain
line. Torque tube nut to 50 65 inch
pounds (5.65 7.34 Nm).
Proper tightening of engine
WARNING tubing connections is criti- (9). Connect fuel inlet line to fuel pump.
cal to flight safety. Correct torque val- Torque hose nut to 230 260 inch
ues must be used at all times. Excessive pounds (25.99 29.38 Nm).
torque on fuel or pneumatic sensing
system connections can result in crack- NOTE: Ensure burner drain valve and plug are
ing of the flare causing an air leak installed in combustion chamber with an O
which can cause flameout, power loss, ring on each part. Ensure drain valve is in
or overspeed. the aft (lowest) position.
(1). Connect torquemeter oil line to (10). Install combustion chamber drain line
firewall. on drain valve.
Page 405
710030 Revision 34
MAINTENANCE MANUAL
ROTATED
UPPER ENGINE MOUNT INSTALLATION
UPPER ENGINE
MOUNT FITTING
(REF. SEC. 712000) UPPER ENGINE MOUNT
SIDE ENGINE MOUNT

ATTACH FITTING
LANDING GEAR
DAMPER FITTING
(REF. SEC. 712000)
LOWER ENGINE MOUNT INSTALLATION
ENGINE FITTING
LOWER ENGINE MOUNT
LOWER ENGINE MOUNT

ATTACH FITTING
(REF. SEC. 712000)
G710004A
Figure 402. Engine Mounts and Structural Fittings
Page 406
Revision 34 710030
MAINTENANCE MANUAL
(11). Secure engine electrical harness to (19). Perform an antiicing system opera-
engine mount with cushioned loop tional check (Ref. Sec. 751000).
clamp. Connect harness plug to recep-
tacle and safety with lockwire (CM702). (20). Inspect engine installation and connec-
tions for proper routing and security.
(a). Install engine harness ground lead.
3. Engine Stripping
(b). Install E, C, and B generator leads on
(Ref. Figure 403)
startergenerator terminal block
with washers and nuts.
Special Tools
(c). Attach thermocouple leads to termi- (Ref. Section 910000)
nal block studs located on right upper Item Nomenclature
engine door frame with chromel and ST401 Engine stand
alumel nuts.
ST402 Engine hoist
(12). Install cooling air ducts and air duct
support bracket on airframe hoist (1). Install engine in engine stand (ST401).
fitting. Connect and tighten ducts on
firewall coupling and oil cooler deflec- (2). Disconnect wire leads from generator A,
tor. E and D terminals.
(13). Install main transmission drive shaft (3). Loosen mounting clamp and remove
(Ref. Sec. 631000). startergenerator.
(14). Install exhaust duct (Ref. Sec. (4). Remove mounting flange and gasket.
783000). (5). Install cover on generator mounting
pad.
(15). Remove all identifying tags from wires
and hardware. (6). Disconnect electrical connectors from:
Improper rigging of throttle con- (a). Chip detectors.
CAUTION trols can cause inadvertent
flameout when throttle is rapidly closed to (b). Tachometer generators.
the idle position. (c). Fuel filter pressure switch.
(16). Rig gas producer (N1) and power (d). Unplug electrical harness connector
turbine (N2) controls (Ref. Chap. 76). from front of engine.
After each opening, removal (e). Unclamp and remove engine electri-
WARNING or replacement of any part cal harness.
of the engine and/or aircraft fuel sys-
tem between the aircraft fuel tank and NOTE: Discard all used Oring packings.
the engine fuel nozzle, the fuel system (7). Remove oil vent line and associated
must be bled to remove trapped air. hardware.
Failure to comply with this procedure
can result in engine flameout or power (8). Remove fuel inlet fitting.
loss.
(9). Remove oil supply, return and vent
(17). Perform fuel system bleed. reducers/unions.
(10). Remove oil pressure reducer/snubber.
per the Pilots Flight Manual. (11). Remove torquemeter reducer/snubber.
NOTE: Make engine adjustments per the Alli- (12). Unclamp and remove compressor bleed
son Engine Operation and Maintenance service line, fitting and associated
Manual. clamps.
Page 407
710030 Revision 22
MAINTENANCE MANUAL
SCREEN FITTING
ASSEMBLY
NUTPLATE
FITTING
SPACER ENGINE OIL

(NOTE) OUTLET
INLET-
SEAL ENGINE OIL
PRESSURE
INLET
BELL
ENGINE OIL
INLET NUTPLATE
PLUG
ENGINE MOUNT
PAD ASSEMBLY
GAS PRODUCER
TURBINE
TACH/GEN (N1)
ENGINE OIL SUPPORT
TANK VENT ASSEMBLY
POWER TURBINE
TACH/GEN (N2)
TORQUEMETER
OIL PRESSURE
PACKING
SEAL BACKING
BOLT
COUPLING
SHIM
CLUTCH
ASSEMBLY
NOTE:
SPACER BONDED TO INLET SEAL.
G7100051A
Figure 403. Model 250C30 Engine BuildUp (Sheet 1 of 2)
Page 408
Revision 22 710030
MAINTENANCE MANUAL
ENGINE BLEED AIR

ASSEMBLY
REF.
FITTING
HI
POINTER
LO
VIEW LOOKING AFT
FUEL FLOW STOP ADJUSTER
TUBE ASSEMBLY
STARTER/GENERATOR ENGINE MOUNTING

PAD ASSEMBLY
GASKET
FITTING
SWITCH
REDUCER
HOSE ASSEMBLY
G7100052A
Figure 403. Model 250C30 Engine BuildUp (Sheet 2 of 2)
Page 409
710030 Revision 22
MAINTENANCE MANUAL
(13). Remove compressor bleed duct from (1). Review Allison instructions for remov-
bleed valve. ing engine from shipping container in
Allison Operation and Maintenance
(14). Unfasten and remove N1 and N2 Manual.
tachometer generators and gaskets.
Prevent FOD Inspect and clean
(15). Remove hose and reducer from fuel CAUTION all accessories and hardware
pump after filter (AF) port.
prior to installing parts on engine.
(16). Remove fuel pressure switch and fitting
from fuel pump before filter (BF) port NOTE: Replace Orings and gaskets with new
(Ref. Figure 403). parts. Lubricate fuel line packings with
clean jet fuel or petrolatum (CM114) prior to
(17). Remove engine air inlet bell and installation. Lubricate oil line packings with
firewall seal. Cover engine inlet. clean engine oil prior to installation. Apply a
thin coating of antiseize compound
(18). Remove fuel pump seal drain port (CM113) to the male threads of unions and
union/reducer. fittings before torquing.
(19). Remove governor control idler support (2). Install engine hoist fitting and bolts.
complete with bellcrank, short N2 Torque 3/8 inch diameter bolt to 160
control rod and lever. Do not dismantle 190 inchpounds (18.08 21.47 Nm).
assembly. Torque 5/16 inchdiameter bolts to 140
(20). Remove overrunning clutch and clutch 160 inchpounds (15.82 18.08
firewall seal. Install cover on gear case. Nm).
(21). Hoist (ST402) engine out of engine (3). Hoist engine clear of shipping contain-
stand. er.
(22). Unbolt and remove engine mount (4). Inspect engine as follows:
fittings.
(a). If shipping container moisture
(23). Install engine in shipping container. indicator was other than a light blue
color, examine engine for corrosion.
(24). Unbolt and remove hoist fitting.
Perform corrosion corrective mainte-
4. Engine Buildup nance per Allison Operation and
Maintenance Manual as required.
(Ref. Figure 403)
(b). Inspect inlet guide vanes for damage.
Consumable Materials (c). Exhaust and inlet openings for FOD.
Item Nomenclature (d). Turbine blades for damage.
CM114 Petrolatum (e). Install covers over intake and
exhaust ports.
CM118 Grease
CM502 Sleeving, fiberglass (f). All fasteners for security, slippage
CM702 Lockwire CRES marks for alignment, potting com-
CM808 Lacing cord pound and, or correctly installed
lockwire where applicable.
Special Tools
(g). Tubes and hoses for damage.
Item Nomenclature (5). Record engine serial number and
ST401 Engine stand startcounter reading in appropriate
log.
Page 410
Revision 22 710030
MAINTENANCE MANUAL
Prevent damage to machined Torque nuts to 70 90 inchpounds

CAUTION surfaces and contamination. Re- (7.91 10.17 Nm).
quired by the installation sequence. Proper tightening of engine
WARNING tubing connections is criti-
(6). Install side engine mount fittings with cal to flight safety. Correct torque val-
bolts and washers. Torque bolts to 140 ues must be used at all times. Excessive
160 inchpounds (15.82 18.08 Nm); torque on fuel or pneumatic sensing
lockwire bolts. system connections can result in crack-
(7). Install engine in engine stand (ST401). which can cause flameout, power loss,
or overspeed.
(8). Set fuel flow stop adjuster as follows:
(16). Inspect torquemeter and engine oil
(a). For Bendix P/N 25249445 or pressure snubber and reducer bores for
25249227 and subsequent, set metal shavings and debris. Clean
pointer at LO position. hardware as required. Preassemble
both snubbers as follows:
(b). For Bendix P/N 25249441, 2, 3,
4 or 25249223, 4, 5, 6, set (a). Thread torquemeter snubber onto
pointer midway between LO stamped reducer and Oring. Torque assembly
mark and the middle scribed mark. to 65 75 inchpounds (7.34 8.47
Nm).
(c). Torque jam nut to 20 25 inch
pounds (2.26 2.82 Nm); lockwire (b). Thread oil pressure snubber onto
nut. reducer and Oring. Torque assembly
(9). Remove cover from gearcase clutch 11.86 Nm).
mounting pad.
(c). Apply a thin coat of engine oil to
(10). Install overrunning clutch on gearcase snubber threads and Orings and
mount pad with wire harness support install in gearcase ports (Ref.
angle between 4 and 5 oclock position Figure 403)
looking aft (Ref. Sec. 631000). The gear case is magnesium
CAUTION alloy. Using relatively high
(11). Loosely attach wire harness clamp to
torque values applicable to threaded fittings
support angle with screw, washer and
and fasteners in metals other than magne-
nut.
sium may result in stripped threads. Refer
(12). Attach clutch firewall seal to clutch to Allison Engine Maintenance Manual for
flange with one washer under each bolt additional fastener torque information.
head and nut. Torque nuts to 25 35 (d). Torque oil pressure snubber assembly
inchpounds (2.82 3.95 Nm). to 50 65 inchpounds (5.65 7.34
NOTE: Use new Oring packings and gaskets Nm).
on all installations where the parts are re- (e). Torque torquemeter snubber assem-
quired. Lubricate Orings with clean sys- bly to 25 35 inchpounds (2.82
tem fluids prior to installation. 3.95 Nm).
(13). Remove tachometergenerator cover (f). Install union and Oring in gearcase
plates from gearcase mount pads. oil supply (inlet) port. Torque union
(14). Install a gasket under each tachome- 56.49 Nm).
tergenerator.
(g). Install union and Oring in gearcase
(15). Lubricate splines with grease (CM118) oil return port. Torque union to 180
and install N1 and N2 tachometer 200 inchpounds (20.34 22.60
generators. Install washers and nuts. Nm).
Page 411
710030 Revision 22
MAINTENANCE MANUAL
(17). Install compressor bleed air duct with (27). Assemble differential pressure switch.
screws washers and clamp (Ref.
Figure 401). (28). Install elbow with Oring and jamnut
in fuel pump seal drain port.
(18). Install inlet bell with one washer under
each bolt head and nut. Install service (29). Install oil inlet and outlet couplings and
bleed air tube support bracket on aft Orings.
surface of engine inlet bell mounting (30). Install fuel inlet reducer and Oring.
flange at the 2 oclock position looking
aft. Torque nuts to 5 7 inchpounds (31). Install starter/generator.
(0.56 0.79 Nm).
Always support the weight of
Only hightemperature self CAUTION the starter/generator during re-
CAUTION locking all metal nuts shall be moval/installation. Damage can occur if
used to fasten governor control idler support weight is supported by the shear shaft.
bracket to engine accessory pad.
(a). Remove starter/generator pad cover.
(19). Install governor control idler support Install starter/generator mount with
complete with bellcrank, short N2 gasket, washers and nuts. Torque
control rod and lever. nuts to 100 140 inchpounds
(11.29 15.81 Nm).
(20). Attach short control rod to N2 governor
lever. Stack hardware with bolt head on (b). Install starter/generator with V
top, large washer under bolt head and clamp. Torque clamp nut to 50
washer under castellated nut; Install inchpounds (5.64 Nm).
cotter pin.
(c). Tap around clamp with a rawhide
(21). Install compressor bleed air service mallet to seat clamp on flange.
fitting on compressor case with engine Retorque clamp nut to 50 inch
supplied washers and bolts. Lockwire pounds (5.64 Nm).
bolts.
(d). Continue tapping around clamp and
(22). Attach bleed air tube to service fitting. retorquing clamp nut until nut no
(23). Install clamp on bleed air tube and applied.
secure to support bracket with bolt,
washer and nut. Torque bleed air tube (32). Clamp engine electrical harness to
nut on compressor case fitting to 450 lower engine mount and startergener-
500 inchpounds (50.84 56.49 Nm). ator.
Install a protective cap on tube end. (33). Connect ignition exciter wire lead and
(24). Install union and Oring in engine oil startergenerator A and D wire leads.
tank vent gearcase boss. Torque union (34). Attach electrical connectors to both chip
to 180 200 inchpounds (20.34 detectors and safety with lockwire
22.60 Nm). (CM702).
(25). Preassemble oil tank vent tube, clamp, (35). Connect N1 and N2 tachometer genera-
union and hose. Torque union, hose and tors.
tube end nuts to 450 500 inch
pounds (50.84 56.49 Nm). (36). Connect start counter lead and fuel
pressure switch wire lead splices.
(26). Attach vent tube assembly to oil tank Install fiberglass sleeving (CM502) over
vent gearcase union. Install tube clamp splices and secure with high tempera-
with screw, washer and nut. Using a ture lacing cord (CM808).
backup wrench to hold union, torque
tube nut to 450 500 inchpounds (37). Inspect engine connections for security
(50.84 56.49 Nm). and proper routing.
Page 412
Revision 26 710030
MAINTENANCE MANUAL
Section
710047
Power Plant
(250C47)
MAINTENANCE MANUAL
POWER PLANT
1. Power Plant Description centrifugal flow compressor section, a
canannular combustion section, a
(1). MDHI 600N helicopter is powered by a twostage gas producer turbine section
250C47M turboshaft engine manufac- and power and accessory gearbox. The
tured by the Allison Engine Company gas producer geartrain drives the
Inc. compressor, hydromechanical control
unit, fuel pump and internal pressure
(2). The engine is secured in the helicopter
and scavenge oil pumps. An overrun-
by three mount assemblies and ac-
ning clutch, drive shaft, starter genera-
cessed through two hinged airsealed
tor, fuel, oil, drain and bleed air lines,
doors.
exhaust ducting, mounting and hoist
(3). A beltdriven blower forces external fittings and control levers adapt the
cooling air through strategically engine to the helicopter.
positioned ducts that direct the air onto
engine exterior surfaces and through (2). Allison Engine Operation and Mainte-
the engine and transmission oil cooler nance Manuals are the primary
heat exchangers. Spent cooling air is information source for engine fault
exhausted aft through an annular isolation and maintenance data (Ref.
opening between the engine exhaust Sec. 010000). Refer to these manuals
duct and fuselage. for specific engine maintenance proce-
dures.
(4). Engine intake air may be filtered
through a standard screen or optional (3). Starter operational limitations are in
air particle separator assembly. Intake the applicable Pilots Flight Manual.
air is drawn through a plenum chamber
and into the engine intake bellmouth 3. Model 250C47 Power Plant Fault
by the compressor. Engine compart- Isolation
ment air is separated from compressor
intake air by a seal ring. (Ref. Table 1)
(5). The engine is equipped with a full (1). Check engine support systems, i.e.; chip
authority digital engine control (FA- detectors, instruments, fuel supply,
DEC) system. A hydromechanical electrical systems, etc., to ensure that
control manual system is provided for helicopter equipment is functioning
backup if the electronic system fails. correctly before disassembling engine
systems for an indicated fault.
2. Power Plant Operation
(2). Inspect and isolate engine problems per
(1). The Allison 250C47M turboshaft the applicable Allison Engine Operation
engine consists of a single stage and Maintenance Manual.

Symptom Probable trouble Corrective action
High frequency vibration (1) Loose engine mount bolts Retorque engine mount bolts to 100
140 inchpounds (11.30 15.82
Nm).
NOTES:
Page 1
710047 Revision 22
MAINTENANCE MANUAL
GENERATOR / STARTER CIRCUIT 6G710641
Figure 1. Starter/Generator System Wiring Diagram (Sheet 1 of 2)
Page 2
Revision 22 710047
MAINTENANCE MANUAL
GENERATOR / STARTER CIRCUIT 6G710642
Figure 1. Starter/Generator System Wiring Diagram (Sheet 2 of 2)
6G71079
Figure 2. Engine Wire Harness Wiring Diagram
Page 3/(4 blank)

710047 Revision 22
MAINTENANCE MANUAL
POWER PLANT
1. Model 250C47 Engine Replacement (5). Loosen clamps and remove engine
cooling air ducts from engine compart-
A. Engine Disconnecting for Removal ment.
(Ref. Figure 401 and Figure 402) (6). Loosen clamps and remove compressor
bleed hose from engine compartment.
After each opening, removal (7). Detach engine electrical connections.
of the engine and/or aircraft fuel sys- (a). Detach engine electrical harness
tem between the aircraft fuel tank and connector.
the engine fuel nozzle, the fuel system
must be bled to remove trapped air. (b). Detach electrical connections from
Failure to comply with this procedure starter/generator.
can result in engine flameout or power (c). Detach splice connector from fuel
loss. filter bypass switch.
Cap fluid lines and fittings with (8). Disconnect fuel inlet line at engine
CAUTION approved devices. Do not use mounted fuel pump.
tape to cover fuel and oil openings. Tape
adhesives loosened by fuel or oil can con- (9). Disconnect hydromechanical unit
taminate systems. (HMU) vent line and drain line.
(10). Disconnect customer bleed air line at
(1). Set all switches OFF. Disconnect
firewall elbow.
external power. Disconnect battery (Ref.
Sec. 960500). (11). Disconnect torquemeter oil line at
firewall.
NOTE: Tag all hardware, wire terminals, fuel
and oil lines before removal to expedite in- (12). Disconnect oil pressure indicator line at
stallation. Identify and bag loose parts to firewall.
prevent loss or damage.
(13). Disconnect engine control cable from
(2). Remove main transmission drive shaft engine control box on HMU.
(Ref. Sec. 631000). The oil cooler is fragile. Unless
CAUTION otherwise required, disconnect
(3). Remove engine exhaust duct (Ref. Sec. oil supply and return lines only at engine.
783000). Cover engine exhaust Support oil cooler port boss with a backup
outlet. wrench when oil line removal is required.
Do not strain or bend unsupported tubes.
(4). Loosen clamps and remove starter
cooling air duct from engine compart- (14). Disconnect engine oil inlet, outlet and
ment. vent lines.
Page 401
710047 Revision 22
MAINTENANCE MANUAL
INLET SEAL ENGINE HOIST FITTING
INLET
BELL
SEAL
ASSEMBLY LEFT SIDE SHOWN
CLUTCH
ASSEMBLY ENGINE MOUNT PAD
6G710661A
Figure 401. Engine Buildup Assembly (Sheet 1 of 2)
Page 402
Revision 22 710047
MAINTENANCE MANUAL
CUSTOMER
BLEED AIR HYDROMECHANICAL
LINE FUEL CONTROL UNIT
ENGINE
OIL TANK
VENT LINE
ENGINE OIL PERMANENT

PRESSURE MAGNET
ENGINE OIL ALTERNATOR
INLET
FUEL FILTER ENGINE

ASSEMBLY CONTROL
ENGINE OIL BOX
OUTLET
STARTER/
GENERATOR
FUEL DIFFERENTIAL
PRESSURE SWITCH
OIL FILTER
ASSEMBLY
VIEW LOOKING AFT VIEW LOOKING FORWARD
ORING ORING
REF. CLUTCH ASSEMBLY
BOLT
POWER TAKEOFF
PAD COVER
LOOKING INBOARDLEFT SIDE
6G710662A
Figure 401. Engine Buildup Assembly (Sheet 2 of 2)
Page 403
710047 Revision 22
MAINTENANCE MANUAL
EXHAUST DUCT
EXHAUST
SUPPORT
ASSEMBLY
COMBUSTOR DRAIN
ENGINE DOOR
ASSEMBLY
ELECTRICAL HARNESS
PRESSURE TRANSDUCER
BULKHEAD UNION
WASHER (2X)
NUT
ENGINE OIL PRESSURE LINE
ENGINE TORQUEMETER LINE
6G710671A
Figure 402. Engine Installation (Sheet 1 of 2)
Page 404
Revision 22 710047
MAINTENANCE MANUAL
FUEL FILTER FUEL IN PORT
OIL OUT PORT

OIL FILTER
FUEL OUT PORT
OIL IN PORT
(EXISTING HOSE)
OIL TANK
ENGINE VENT
CONNECTION
CUSTOMER
BLEED AIR
ENGINE OIL IN CONNECTION
CONNECTION
ENGINE OIL OUT

CONNECTION
(EXISTING HOSE)
6G710672
Figure 402. Engine Installation (Sheet 2 of 2)
Page 405
710047 Revision 22
MAINTENANCE MANUAL
B. Removal of Disconnected Engine transport and storage bar to engine

hoist fitting.
C. Engine Installation in Mounts
Special Tools (Ref. Figure 401 and Figure 402)
Item Nomenclature
ST401 Engine stand (Ref. Section 910000)
ST402 Engine hoist Item Nomenclature
CM702 Lockwire CRES
CAUTION Special Tools

D Do not remove engine mounts or disturb Item Nomenclature
engine mount adjustments to remove en-
gine. ST401 Engine stand
ST402 Engine hoist
D Engine to transmission alignment shall
be inspected whenever one or more en-
gine mount assemblies is replaced or the (1). Open engine access doors.
existing alignment is disturbed. Do not
disturb adjustable engine mount fittings (2). Position engine to line up engine hoist
unless an enginetransmission align- fitting under airframe hoist fitting.
ment check is planned. (3). Remove detent pin from adjustable
support shaft on engine stand. Detach
(1). Install engine hoist tool (ST402)
between engine hoist fitting and
hoist fitting.
airframe hoist fitting.
(4). Install engine hoist (ST401) between
(2). Apply tension to engine with hoist and airframe fitting and engine hoist
remove engine mount bolts. fitting.
Do not use fuel or oil lines as (5). Apply tension to engine hoist to support
CAUTION hand holds. Do not allow engine engine. Unscrew engine stand adjust-
to strike airframe while maneuvering it out able support shaft.
of the helicopter.
(6). Move engine to disengage fixed shaft.
(3). Align engine stand (ST401) under Roll stand away from engine.
engine with adjustable support shaft on
left side. CAUTION
(4). Slowly lower engine out of helicopter. D Do not use tubes or hoses as hand holds.
Align engine side mount fittings Do not allow engine to strike airframe or
between fixed and adjustable support components. Avoid damaging engine in-
shafts. take bell.
(5). Screw in adjustable support shaft until D Prevent FOD. Ensure that no foreign ob-
engine mount fittings are securely jects are in the engine plenum area.
engaged with support shaft sockets.
(7). Slowly raise engine while pushing back
(6). Insert detent pin through adjustable of engine down to maintain correct
support shaft. engine and transmission alignment.
(7). Remove hoist from engine hoist fitting. (8). Align left and right engine mount
assemblies with engine mount fittings.
(8). If engine is to be stored or transported, Install bolts and washers (Ref.
secure upper end of engine stand Figure 403). Torque bolts to 220 360
Page 406
Revision 22 710047
MAINTENANCE MANUAL
inchpounds (24.85 40.66 Nm). tube nut to 75 85 inchpounds (8.47

Safety bolts with lockwire (CM702). 9.60 Nm).
(9). Align hole in lower engine mount (2). Connect oil pressure gauge line to
assembly with engine fitting. Install bulkhead union on firewall. Torque tube
bolt, washers and nut. Torque nut to 95 nut to 75 85 inchpounds (8.47
110 inchpounds (10.73 12.43 9.60 Nm).
Nm).
(3). Connect engine oil vent line. Torque
(10). Ensure inlet seal assembly contacts hose nut to 230 260 inchpounds
firewall around its entire circumfer- (25.98 29.36 Nm).
ence.
Do not bend oil return line.
(11). Remove hoist from helicopter. CAUTION Bending loads are transferred to
(12). Perform engine to transmission
alignment if applicable (Ref. CSP (4). Connect engine oil out line to elbow.
SRM6, Section 533000). Torque hose nut to 230 260 inch
(13). Using a mirror and light, check for pounds (25.98 29.36 Nm).
clearance between airframe and bleed (5). Connect engine oil in line to union.
valve, any clearance is acceptable. Torque hose nut to 460 500 inch
(14). If bleed valve contacts firewall, readjust pounds (51.96 56.48 Nm).
engine mounts for clearance. (6). Connect customer bleed air line to
(a). Move engine back by adjusting the elbow. Torque hose nut to 460 500
left and right mounts, increasing the inchpounds (51.96 56.48 Nm).
top and decreasing the bottom.
(7). Connect engine fuel pump seal drain
(b). Only make adjustments one flat at a line. Torque tube nut to 50 65 inch
time until bleed valve clears firewall. pounds (5.64 7.34 Nm).
NOTE: One flat will move the engine approxi- (8). Connect fuel inlet line to fuel pump.
mately 0.020 inch (0.508 mm) aft. Torque hose nut to 230 260 inch
pounds (25.98 29.36 Nm).
(c). Adjust lower mount to insure no
preload exists. NOTE: Ensure burner drain valve and plug are
installed in combustion chamber with an O
(d). Perform engine to transmission ring on each part. Ensure drain valve is in
alignment if applicable (Ref. CSP the aft (lowest) position.
SRM6, Section 533000).
(9). Install combustion chamber drain line
D. Connecting an Installed Engine on drain valve. Torque tube nut to 50
Proper tightening of engine (10). Attach engine electrical connectors.
(a). Attach engine electrical wire harness
cal to flight safety. Correct torque val- to to airframe connector at firewall.
ues must be used at all times. Excessive
torque on fuel or pneumatic sensing (b). Attach fuel pressure bypass switch
system connections can result in crack- splice connector.
which can cause flameout, power loss, (c). Attach starter/generator electrical
or overspeed. connections (Ref. Figure 403).
(1). Connect torquemeter indicator oil line (11). Install main transmission drive shaft
to bulkhead union on firewall. Torque (Ref. Sec. 631000).
Page 407
710047 Revision 36
MAINTENANCE MANUAL
STARTER / GENERATOR (20). Inspect engine installation and connec-

tions for proper routing and security.
D
2. Model 250C47 Engine Stripping
E P1063A0N E12
A (Ref. Figure 401)
B
C
Special Tools
K1062A0 (Ref. Section 910000)
P1061A0 Item Nomenclature
P1054A18
P1052A22 ST401 Engine stand
6G71085 ST402 Engine hoist
Figure 403. Starter/Generator Electrical
Connections Cap fluid lines and fittings with
CAUTION approved devices. Do not use
(12). Install cooling air ducts and air duct tape to cover fuel and oil openings. Tape
support bracket on airframe hoist adhesives loosened by fuel or oil can con-
fitting. Connect ducts and tighten taminate systems.
clamps on firewall coupling and oil
cooler deflector.
NOTE: Discard all used Oring packings.
(1). Remove engine control box from HMU.
(13). Install compressor bleed hose and
tighten clamps. (2). Remove reducers from HMU.
(3). Remove starter/generator.
(14). Install starter cooling air duct and
tighten clamps. Always support the weight of
CAUTION the starter/generator during re-
(15). Install exhaust duct (Ref. Sec. 7800). moval/installation. Damage can occur if
weight is supported by the shear shaft.
(16). Connect and rig engine control cable
(Ref. Chap. 76). (a). Loosen Vclamp and remove starter/
generator.
After each opening, removal (b). Remove bolts, washers, mounting
flange and gasket.
of the engine and/or aircraft fuel sys-
tem between the aircraft fuel tank and (4). Remove oil vent line and associated
the engine fuel nozzle, the fuel system hardware.
must be bled to remove trapped air.
Failure to comply with this procedure (5). Remove fuel inlet fitting.
can result in engine flameout or power (6). Remove unions from oil in port and oil
loss. tank vent unions from gearcase.
(17). Perform fuel system bleed (Ref. Chap. (7). Remove oil pressure tube, clamps and
28). attaching hardware and reducer/snub-
ber.
per the Pilots Flight Manual. (8). Remove torquemeter tube, clamps and
attaching hardware and expander.
NOTE: Make engine adjustments per the Alli- (9). Remove customer bleed air line,
son Engine Operation and Maintenance associated clamps and hardware and
Manual. fitting.
(19). Perform an antiicing system opera- (10). Remove N1 and N2 tachometer genera-
tional check (Ref. Chap. 75). tors and gaskets.
Page 408
Revision 29 710047
MAINTENANCE MANUAL
(11). Remove hose, fuel pressure switch,

reducers, tee fitting and union from fuel CAUTION
filter assembly. D Prevent FOD. Inspect and clean all acces-
sories and hardware prior to installing
(12). Remove engine air inlet bell and parts on engine.
firewall inlet seal. Cover engine inlet.
D The gear case is magnesium alloy. Using
(13). Remove overrunning clutch and clutch relatively high torque values applicable to
firewall seal. Install cover on gear case. threaded fittings and fasteners in metals
other than magnesium may result in
(14). Hoist engine and remove engine stand. stripped threads. Refer to Allison Engine
Maintenance Manual for additional fas-
(15). Unbolt and remove engine mount tener torque information.
fittings. (b). Install engine hoist fitting and bolts.
Torque bolts to 140 160 inch
(16). Install engine in shipping container. pounds (15.81 18.07 Nm).
(17). Unbolt and remove hoist fitting. (c). Install engine hoist tool (ST402)
between engine hoist fitting and
3. Model 250C47 Engine Buildup airframe hoist fitting.
(d). Raise engine off shipping container
(Ref. Figure 401)
base.
Proper tightening of engine (2). Inspect engine as follows:
cal to flight safety. Correct torque val- (a). If shipping container moisture
ues must be used at all times. Excessive indicator was other than a light blue
torque on fuel or pneumatic sensing color, examine engine for corrosion.
system connections can result in crack- Perform corrosion corrective mainte-
ing of the flare causing an air leak nance per Allison Operation and
which can cause flameout, power loss, Maintenance Manual as required.
or overspeed. (b). Inlet guide vanes for damage.
(c). Exhaust and inlet openings for FOD.
(Ref. Section 910000) (d). Install covers over intake and
Item Nomenclature exhaust ports.
CM111 Grease, aircraft (e). All fasteners for security, slippage
CM126 Oil, turbine marks for alignment, potting com-
pound and, or correctly installed
CM702 Lockwire CRES
lockwire where applicable.
Special Tools (f). Tubes and hoses for damage.

(Ref. Section 910000) (3). Record engine serial number and
Item Nomenclature startcounter reading in appropriate
ST401 Engine stand log.
ST402 Engine hoist Prevent damage to machined
CAUTION surfaces and contamination. Re-
(1). Prepare engine for buildup as follows: quired by the installation sequence.
(a). Review Allison instructions for (4). Install engine mount fittings with bolts
removing engine from shipping and washers. Torque bolts to 140 160
container in Allison Operation and inchpounds (15.81 18.07 Nm).
Maintenance Manual. Safety bolts with lockwire (CM702).
Page 409
710047 Revision 29
MAINTENANCE MANUAL
(5). Install engine in engine stand (ST401). (8). Install expander with Oring on
existing engine torquemeter line fitting.
(6). Install clutch assembly. Torque expander to 50 70 inch
pounds (5.64 7.90 Nm).
(a). Remove engine power take off pad
cover from aft side of engine gearbox (9). Install engine oil tank vent line.
and protective cover from forward (a). Install union with Oring in engine
side of engine gearbox. gearcase oil tank vent port. Torque
(b). Lubricate clutch assembly and union to 280 305 inchpounds
engine power output shaft splines (31.62 34.45 Nm).
before assembly. Pack all voids and (b). Install oil tank vent tube on union.
gaps with grease (CM111). Torque tube nut to 230 260 inch
pounds (25.98 29.36 Nm).
(c). Install clutch assembly with angle,
washers and nuts. Torque nuts to 50 (c). Install union on oil tank vent tube.
70 inchpounds (5.64 7.90 Nm). Torque union to 230 260 inch
pounds (25.98 29.36 Nm).
Use caution when installing bolt
CAUTION to avoid cutting Oring. Liberal-
(d). Install vent hose on union. Torque
hose nut to 230 260 inchpounds
ly coat Oring with grease and install with (25.98 29.36 Nm).
twisting motion.
(10). Install union with Oring in engine
NOTE: Use new Oring packings and gaskets gearcase oil inlet port. Torque union to
on all installations where the parts are re- 550 600 inchpounds (62.12 67.77
quired. Lubricate Orings with clean sys- Nm).
tem fluids prior to installation.
(11). Install customer bleed air line.
(d). Lubricate Orings with grease (a). Install customer bleed air fitting with
(CM111) and install on bolt. Install engine supplied gasket, washers and
bolt in aft end of engine power output engine supplied bolts. Torque bolts to
shaft. Thread bolt into clutch shaft 20 25 inchpounds (2.25 2.82
and torque bolt to 250 300 inch Nm). Safety bolts with lockwire
pounds (28.24 33.88 Nm). (CM702).
(e). Reinstall engine power take off pad (b). Install bleed hose assembly on bleed
cover. Torque nuts to 50 70 inch air fitting. Torque hose assembly to
pounds (5.64 7.90 Nm). 230 260 inchpounds (25.98
29.36 Nm). Clamp line to strap
NOTE: Install firewall seal with split at 6 attached to inlet bell mount bolt.
Oclock position.
(12). Install fuel switch.
(f). Install seal at end of clutch assembly (a). Install union with Oring in fuel
with washers and screws. Torque filter housing. Torque union to 95
screws to 15 20 inch pounds (1.69 105 inchpounds (10.73 11.86
2.25 Nm). Nm).
To avoid contamination of en- (b). Install tee on union with Oring and
CAUTION gine oil system, inspect reducer jam nut. Torque jam nut to 38 42
and snubber bores for metal shavings and inchpounds (4.29 4.74 Nm).
debris. (c). Install reducer with Oring on end of
(7). Install engine oil pressure snubber, tee. Torque reducer to 95 105
reducer and Oring on engine gearbox. inchpounds (10.73 11.86 Nm).
Connect oil pressure tube to snubber. (d). Install union with Oring on 90
Torque tube nut to 20 30 inch degree fitting of tee. Torque restrictor
pounds (2.25 3.38 Nm). Clamp tube to 95 105 inchpounds (10.73
to existing engine line. 11.86 Nm).
Page 410
Revision 29 710047
MAINTENANCE MANUAL
(e). Install fuel switch with Oring on (c). Tap around clamp with a rawhide
reducer. Torque switch to 65 75 mallet to seat clamp on flange.
inchpounds (7.34 8.47 Nm). Retorque clamp nut to 50 inch
pounds (5.64 Nm).
(f). Install reducer with Oring in fuel
(d). Continue tapping around clamp and
filter housing. Torque reducer to 95
retorquing clamp nut until nut no
105 inchpounds (10.73 11.86
Nm).
applied.
(g). Install hose between fuel switch and (15). Install engine control box on HMU.
reducer. Torque hose nuts to 20 30
inchpounds (2.25 3.38 Nm). (a). Hold engine control box in position
against HMU.
(13). Install inlet bell and inlet seal with (b). Insert 0.15350.1545 inch
bolts, washers and nuts. Torque nuts to (3.89893.9243 mm) rig pin (#23 drill
60 85 inchpounds (6.77 9.60 blank) through engine control box,
Nm). indexed HMU pointer and into HMU.
(14). Install starter/generator. (c). Rotate serrated washer on shaft for

microadjustment until rig pin
inserts without interference.
Always support the weight of
CAUTION the starter/generator during re- (d). Install mounting bolts, washers and
moval/installation. Damage can occur if use shim washers as required
weight is supported by the shear shaft. between engine control box and HMU
to prevent binding on rig pin. Torque
(a). Remove starter/generator pad cover. bolts to 36 46 inchpounds (4.06
Install starter/generator mount with 5.19 Nm).
gasket, washers and nuts. Torque
(e). Check rig pin fit again and repeat
nuts to 100 140 inchpounds
previous steps as required.
(11.29 15.81 Nm).
(16). Install reducers with Orings on HMU.
(b). Install starter/generator with V Torque reducers to 550 600 inch
clamp. Torque clamp nut to 50 pounds (62.12 67.77 Nm) and 50
inchpounds (5.64 Nm). 55 inchpounds (5.64 6.21 Nm).

710047 Revision 29
MAINTENANCE MANUAL
Section
711000
Engine Air Intake
System (369D/E/FF
500/600N)
MAINTENANCE MANUAL
ENGINE AIR INTAKE SYSTEM

1. Description and Operation intake air from accumulating in the
plenum chamber cavity.
(1). The engine air intake system consists of
an air inlet screen, plenum chamber, 2. Air Inlet Screen Replacement
engine inlet bell, engine inlet firewall
seal, and engine firewall seal ring. A. Air Inlet Screen Removal (369D/E/FF
500N)
(2). Air enters the inlet fairing, passes
(Ref. Figure 201)
through the inlet screen, plenum
chamber and air inlet bell into the NOTE: The following procedures are to be used
engine compressor. for all MDHI model helicopters. The differ-
ent steps are noted for the 500N installa-
(3). The engine inlet screen assembly is tion.
made of a lightweight 1/4 inch (6.35
mm) mesh metal screen material (1). Remove engine air inlet forward
secured to a metal frame along its outer fairings (Ref. Sec. 533000/30).
edge. The engine air particle separator
option, when installed, replaces the (2). Open plenum chamber bypass door.
inlet screen.
(3). Install a suitable cover over engine air
(4). The inlet screen edge is 11/2 inches inlet bell though bypass door opening.
(3.81 cm) from the top of air inlet
(4). On 500N installation, remove the
fairing to provide an intake airbypass
engine plenum fairing attachment
area in the event that debris clogs the
hardware, open bypass door and
screen. The firewall seal separates
remove fairing assembly.
plenum chamber intake air from engine
compartment air. Avoid FOD. Cover compressor
(5). A differential pressure switch is chamber. Vacuum all FOD debris out of ple-
mounted with a reference to both sides num chamber before removing protective
of the engine inlet screen. Blockage of cover from engine inlet bell. Severe damage
the inlet screen will cause a pressure to engine may result from entry of foreign
decrease on the engine plenum side and objects.
the switch will activate a warning light
in the cockpit. (5). Remove clamps or tiedown straps
securing tail rotor control rod boot to
(6). A cable from the cockpit is manually inlet screen fairing.
operated to open a bypass door which
allows unfiltered air into the engine (6). Disconnect Sta. 120.00 tail rotor control
inlet plenum if the engine inlet screen rod forward end. (Ref. Chap. 67).
is blocked.
(7). On 500N disconnect the intermediate
anti torque tube forward end. (Ref. Sec.
(7). The molded nylon air inlet bell is 672030).
retained on its mounting flange with
three flat springs and is required to (8). Remove blower air inlet screen (Ref.
smooth air flow into the compressor. Figure 201).
(8). A plenum chamber drain system (9). Remove attaching hardware and engine
prevents water condensed out of engine air inlet screen.
Page 201
711000 Revision 22
MAINTENANCE MANUAL
FAIRING
ENGINE AIR INLET SCREEN
BOLT
PLENUM CHAMBER
WASHER ACCESS DOOR
SCREW
SCREW
WASHER
WASHER
BLOWER AIR
INLET SCREEN ANTITORQUE CONTROL
ROD BOOT SUPPORT
FAIRING
369D/E/FF INSTALLATION
PLENUM CHAMBER
ACCESS DOOR
ENGINE AIR INLET SCREEN
BOLT
WASHER
SCREW
WASHER
WASHER
BLOWER AIR
INLET SCREEN ANTITORQUE CONTROL
ROD BOOT SUPPORT
500N INSTALLATION
G711021B
Figure 201. Engine Air Inlet Screen Installation (Sheet 1 of 2)
Page 202
Revision 22 711000
MAINTENANCE MANUAL
ENGINE INLET
SCREEN ASSEMBLY ENGINE PLENUM
ACCESS COVER
INLET FRAME
600N INSTALLATION
6G71074
Figure 201. Engine Inlet Screen Installation (Sheet 2 of 2)
Page 203
711000 Revision 22
MAINTENANCE MANUAL
B. Engine Inlet Screen Removal (600N) 4. Firewall Seal Removal

(Ref. Figure 201) (Ref. Figure 202)
(1). Remove screws, washers and inlet
screen from inlet frame. Consumable Materials
C. Air Inlet Screen Installation (369D/E/FF Item Nomenclature
500N) CM219 Methylethylketone
(Ref. Figure 201) CM411 Adhesive, epoxy
Vacuum all FOD debris out of

CAUTION plenum chamber before remov- (1). Remove engine.
ing protective cover from engine inlet bell.
Severe damage to engine may result from (2). Pull seal from firewall.
entry of foreign objects.
Use Methyl ethyl ketone
WARNING (MEK) in a well ventilated
(1). Install engine air inlet screen in reverse
order of removal. area and away from heat and flame.
D. Engine Inlet Screen Installation (600N) (3). Remove seal debris from firewall with a
wooden or plastic scraper.
(Ref. Figure 201)
(4). Remove residue from firewall with
(1). Install inlet screen on inlet frame with MEK (CM219).
washers and screws. Torque screws to
20 25 inchpounds (2.25 2.82 (5). Apply adhesive (CM411) to installation
Nm). per manufacturers instructions. Center
seal over firewall opening and bond in
3. Air Inlet Bell Replacement place.
A. Air Inlet Bell Removal (6). Install engine.
(Ref. Figure 202) 5. Air Intake System Inspection

(1). Remove engine. (1). Inspect air inlet screen for security,
deformation,inspect screen for cleanli-
(2). Remove attaching hardware, air inlet ness, clogged areas and foreign particle
bell and firewall seal ring. accumulation. (Cleaning of engine air
(3). Remove firewall seal ring from inlet inlet screens Ref. Sec. 202000).
bell.
(2). Inspect screen for tears, cuts, breaks
B. Air Inlet Bell Installation and missing pieces.
(Ref. Figure 202) (3). Inspect antitorque control rod boot for
condition and secure attachment (Ref.
(1). Model 250C20B Only: Chap. 67).
On early installations; attach firewall
seal ring to inlet bell by lifting and (4). Inspect air inlet bell for cracks, breaks
positioning leaf springs over bell flange. and missing pieces. No cracks or
missing pieces allowed.
(2). Position engine air inlet bell and seal
assembly on compressor inlet mounting (5). Model 250C20B Only:
flange and secure. On early installations; inspect engine
firewall seal ring for cracked or weak
(3). Install engine. springs.
Page 204
Revision 22 711000
MAINTENANCE MANUAL
SCREW WASHER
AIR INLET BELL
FIREWALL SEAL
FIREWALL SEAL RING
WASHER
NUT
SPACER ENGINE
MOUNTING FLANGE
250C30 AND 250C47 ENGINES
SCREW
FIREWALL SEAL RING
SCREW
WASHER
ENGINE AIR INLET BELL NUT
FIREWALL
WASHER
AIR INLET BELL NUT

FIREWALL SEAL
FIREWALL SEAL
FIREWALL SEAL RING
EARLY CONFIGURATION
250C20B AND 250C20R/2 ENGINES
G711020A
Figure 202. Firewall Seal Installation
Page 205
711000 Revision 22
MAINTENANCE MANUAL
(6). Inspect enginetofirewall seal ring at 6. Firewall Seal Ring Repair

the firewall for cracks, corrosion or
damage preventing a positive and Replace damaged or broken springs on early
complete seal. Repair or replace seal installations.
installation as required.
7. Air Inlet Bell Repair
(7). Inspect air inlettofirewall seal for Engine air inlet bell repairs are not autho-
cracks, corrosion or damage preventing rized; replace a defective bell.
a positive and complete seal. Repair or
replace seal installation as required. 8. Plenum Chamber Drain Tube Replacement
(Ref. Figure 203)
(8). Inspect plenum chamber drain tubing
for deformation and corrosion. Ensure (1). Replace drain tubing using standard
drain is open. practices and procedures.
PLENUM CHAMBER
PLENUM CHAMBER
DRAIN TUBE
FIREWALL FITTING
FIREWALL
LOCKWIRE
FIREWALL
NYLON TWINE
DRAIN TUBE ATTACHMENT
GROMMET
G711022
Figure 203. Drain System
Page 206
Revision 22 711000
MAINTENANCE MANUAL
Section
711005
Engine Compressor
Water Wash Kit
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
ENGINE COMPRESSOR WATER WASH KIT

1. Engine Compressor Water Wash Kit 2. Engine Compressor Water Wash Kit
Maintenance Inspection
(1). Inspect hoses for chafing, damage and
deterioration.
Replace hoses, clamps and other hardware
only when necessary. (2). Inspect all clamps for damage and
security.
Whenever working in the en- (3). Inspect elbow for damage and security.
CAUTION gine plenum area, cover engine (4). Inspect spray assembly for loose rivets,
with cardboard or other suitable object to secure hose and clamp, no damage to
prevent foreign objects from entering en- grommet and silicone sealant around
gine. tube intact.
(5). Inspect all mounting brackets for loose
rivets.
(1). Remove appropriate access panels to
gain access to area of water wash kit to (6). Inspect lanyard for security and
be worked on. damage; cap installed.

711005 Revision 22
MAINTENANCE MANUAL
ENGINE COMPRESSOR WATER WASH KIT

1. Engine Compressor Water Wash Kit Initial (4). Drill or cut 0.4531 inch (11.50874 mm)
Installation hole in firewall assembly at dimension
shown in view AA. Position and install
A. Gaining Access to Work Area AN8484D hose elbow in firewall with
hardware as shown.
(1). In aft compartment, remove seat
assemblies, L/H bulkhead trim, access (5). Cut hole for MS3548911 grommet in
cover and insulation; gearbox access forward wall of plenum chamber per
cover. dimensions shown; install grommet
with sealant (CM430).
(2). Remove engine air inlet forward
fairing; open plenum chamber access (6). Position 369H3042 spray assembly on
door. inner side of plenum chamber forward
wall, view BB, with tube inserted
Install temporary cover of card- forward through grommet. Mark and
CAUTION board or suitable material over drill rivet holes and install spray
engine air intake. assembly with eight NAS1738M42
rivets. Install rivets with primer.
(3). Remove engine air shield screen or
engine air inlet screen, as applicable; (7). Install 369H30485 hose on spray
remove access cover from mast support assembly tube and on hose elbow at
structure panel. firewall; secure hose at each end with
AN737TW22 clamps.
(4). Open L/H engine compartment door.
(8). Mark and drill No. 8 hole in 369H3024
B. Airframe Modification and Installation channel and install MS252814 clamp
and hardware as shown. Secure 5 hose
(Ref. Figure 901) with clamp.
Consumable Materials (9). Install 369H30483 hose on elbow at

(Ref. Section 910000) left side of firewall and on hose adapter
Item Nomenclature at forward side of lower section ring.
Secure hose at each end with
CM318 Primer AN737TW22 clamps.
2. Installation Inspection
(1). Position 369H3047 support on Sta. (1). Carefully check and/or vacuum the
137.50 lower section ring at dimensions plenum chamber for any foreign objects
shown in view EE. Mark and drill or debris. Remove protective cover from
rivet holes and install support with six engine air intake.
NAS1398B42 rivets. Install rivets
with Primer (CM318). NOTE: Spray kit using 369H3042 nozzle re-
quires 60 PSI (414 kPa) to establish water
(2). Drill No. 8 hole in ring assembly; locate flow rate of one quart (0.946 L) in 910 sec-
from existing hole in support. onds. A bypass valve or equivalent installed
at source hose connection is recommended
(3). Install AN8074D hose adapter in in order to relieve pressure and facilitate
support with hardware as shown; disconnection at hose adapter.
install lanyard clip in hole with hard-
ware as shown. Install 369H3046 cap (2). Perform operational check of water
on hose adapter. wash kit installation.
Page 901
711005 Revision 22
MAINTENANCE MANUAL
(3). Reinstall removed components and (4). Record installation of 369H92537

assemblies; install and secure access engine compressor water wash kit in
covers and doors. helicopter Log Book.
STA. STA.
127.00 137.50
C
BL
B
0.22 IN. 0.00
R MS3548911
(5.588 MM) GROMMET (1 REQD)
TYPICAL (DO NOT SPLIT)
0.76 IN.
WL
(19.304 MM) 0.60 IN.
50.00
(15.24 MM)
B
0.38 IN.
(9.652 MM) NOTE
CL ENGINE
HOLE FOR
GROMMET
AN737TW22
CLAMP (2 REQD) AN8484D HOSE ELBOW
1.75 0.10 IN.
(44.45 2.54 MM) AN960PD716L WASHER
369H30485 HOSE AN9244D NUT
A C
D
D
369H3046 CAP AND

LANYARD ASSEMBLY
AN8074D HOSE ADAPTER
AN960PD716L WASHER
AN9244D NUT E
AN737TW22 CLAMP
(2 REQD)
AFT SECTION ASSEMBLY

FUSELAGE STRUCTURE 369H30483 HOSE E
AN737TW22 CLAMP
NOTE: SEAL WITH SILICONE SEALANT. G7110231A
Figure 901. Engine Compressor Water Wash Kit Installation (Sheet 1 of 3)
Page 902
Revision 22 711005
MAINTENANCE MANUAL
BL
10.00
FIREWALL ASSEMBLY
BL
20.00
15
APPROX.
TRACE
WL 40.00
0.453 IN.
(11.5094 MM)
0.79 IN.
(20.066 MM)
3.00 IN.
AA (76.2 MM)
TRACE
CL ENGINE WL 30.00
BL
0.00
INLET ASSEMBLY, ENGINE

0.78 IN. AFT SECTION
(19.812 MM)
NAS1738M42 RIVET 369H3042 SPRAY ASSEMBLY

MFD. HEAD FAR SIDE
LOCATED FROM 369H3042
(8 REQD) (NOTE)
BB
NOTE: ALTERNATE MS206153M5 RIVET

MAY BE USED IN PLACE OF NAS1738M42.
G9610232A
Page 903
711005 Revision 22
MAINTENANCE MANUAL
BL
0.00
WL
50.00
INLET ASSEMBLY,
ENGINE AFT SECTION
RING ASSEMBLY, LOWER

SECTION STA. 137.50
CC 0.1980.204 IN. (NO. 8) DIA. HOLE
(50.2925.1816 MM)
NAS62333 SCREW
WL AN960PD10L WASHER (2 REQD)
34.50 MS252814 CLAMP
MS210423 NUT
0.50 IN.
369H3024 REF (12.7 MM)
0.50 IN.
(12.7 MM)
NAS1398B42 RIVET
LOCATE FROM
369H3047 (6 REQD)
1.18 IN. LBL
(29.972 MM) 8.45
STA. DD
369H3047 SUPPORT 124.00
CANT
0.1980.204 IN.
EE (50.2925.1816 MM) (NO. 8) DIA. HOLE (LOCATED FROM 369H3047)
NAS62333 SCREW
AN960PD10L WASHER
MS210423 NUT
G9610233A
Page 904
Revision 22 711005
MAINTENANCE MANUAL
Section
711010
Engine Air Particle
Separator
(369D/E/FF 500N)
MAINTENANCE MANUAL
ENGINE AIR PARTICLE SEPARATOR

1. Description and Operation Later installations feature a system of
clips that retain the mist eliminator in
(Ref. Figure 1) sealed contact with the particle separa-
tor. The mist eliminator consists of a
(1). MDHI 369/500 helicopters may be welded stainless steel frame and wire
equipped with an optional engine inlet mesh screens on the fore and aft faces.
air particle separator filter installation
in place of the standard engine air inlet (5). Air drawn through the particle separa-
screen. tor by the engine passes through the
parallel vortex tubes. Each tube is
(2). Later model helicopters are equipped fitted with vanes and an opening to the
with a Aircraft Porous Media (APM) particle collection chamber. The vanes
filter. Earlier 500D helicopters were spin the incoming air so that centrifu-
fitted with a Donaldson particle gal force separates heavier solid bits
separator. The APM unit is equipped from the air flow. A smaller diameter
with provisions for an optional mist tube directs particle free center vortex
eliminator installation. tube air through the collection chamber
rear plate into the plenum chamber.
(3). Both the APM and Donaldson particle
When the scavenge air system is
separators are installed inside the front
switched ON, trapped particles are
of the aft intake fairing above the
drawn out of the collection chamber by
plenum chamber and utilize the same
scavenge air vacuum and discharged
operating principle. The particle
overboard through an opening in the
separator installation consists of vortex
right side of the aft inlet fairing of APM
tubes, a collection chamber, a nozzle
equipped helicopters and the left side
manifold, ejectors, flapper valve, seals
on Donaldson equipped machines. The
and attaching hardware. A scavenge air
nozzle manifold is fitted with an engine
system is used to remove trapped
bleed air inlet port and air jets to
particles from the collection chamber
discharge contaminants. The ejector
with engine bleed air. The scavenge air
assembly consists of a mounting flange
system consists of a solenoid air valve,
with tubes, duct assembly and flapper
tubes, an air pressure switch, SCAV
valve.
AIR circuit breaker switch, AIR
FILTER CLOGGED caution light, (6). The scavenge air system is supplied
wiring, and attaching hardware. An air compressor bleed air controlled by the
bypass door system is included to allow solenoid air valve. Bleed air is delivered
the particle separator to be bypassed in to a ductmounted nozzlemanifold
the event the unit becomes clogged. The that ejects contaminants from the
air bypass door system includes a particle separator. The electrically
hinged plenum chamber door, door actuated solenoid air valve is mounted
latches, door actuating forward and aft on the left forward side of the Station
cables, cable return spring, two retain- 124.00 bulkhead. The valve is con-
ers, three cable pulleys, adjustable trolled by the SCAV AIR circuit breaker
cable stop, handle and attaching switch on the instrument panel.
hardware.
(7). An increase in plenum chamber
(4). An optional mist eliminator may be vacuum (reduced plenum chamber
fitted to the back of APM separators to pressure) caused by reduced airflow
filter liquid sprays out of engine inlet through a clogged filter/mist eliminator
air. Nine self retaining bolts secure is sensed by a differential pressure
early mist eliminator installations to switch ported to the plenum chamber
the aft face of the particle separator. and particle separator inlet. Sufficient
Page 1
711010 Revision 22
MAINTENANCE MANUAL
pressure differential causes the switch retainers on the aft end of the forward
to close. Switch closure lights an AIR cable returns the handle to the stowed
FILTER CLOGGED caution indicator position. An adjustable stop provides
on the instrument panel. A cable for cable travel adjustment and air
actuated filter bypass door on the bypass door rigging.
plenum chamber wall may be opened by
the pilot to allow the engine to operate
on unfiltered air. On 500N installation, the FILTER
BYPASS CONTROL handle in the crew
(8). Pulling the FILTER BYPASS CON- compartment disengages one door latch
TROL handle in the crew compartment inside the air inlet aft fairing and opens
disengages two door latches inside the the door inward. Adjustment of this
engine air inlet aft fairing and opens cable installation is limited by reposi-
the door inward. A spring and two tioning the cable assembly.
Table 1. Engine Air Particle Separator Configurations
Model Part Number Cabin Heat Principal Features

500N 500N901483 No APM filter with new pressure switch and Tpedestal electrical
500N901481 Yes installation.
530FF 369H90148543 No APM filter with generic wire harness and no cabin heat
369H90148541 Yes APM filter with generic wire harness and cabin heat
369H90148529 No APM filter with new pressure switch and Tpedestal electrical
369H90148527 Yes installation.
500E 369H90148545 Yes APM filter for C20R engine with generic wire harness
369H90148539 No APM filter for C20R engine with generic wire harness
369H90148537 No APM filter for C20B engine with generic wire harness
369H90148535 Yes APM filter for C20B engine with generic wire harness
369H90148521 No APM filter with Tpedestal electrical installation.
369H90148519 Yes
500D 369H90148509 No APM filter with electrical controls bracket on side of slimline pedestal.
369H90148507 Yes
369H90148505 No Donaldson filter with electrical controls bracket on side of slimline

369H90148503 Yes pedestal. No mist eliminator option.
Page 2
Revision 36 711010
MAINTENANCE MANUAL
TYPICAL FILTER FUNCTION

(VIEW LOOKING DOWN)
G7110001A
Figure 1. Particle Separator Operating Principle Early Type (Donaldson Unit)
Page 3
711010 Revision 22
G7110002
TYPICAL FILTER FUNCTION
FILTER BYPASS CONTROL
(VIEW LOOKING DOWN) FILTER TUBE DETAIL VIEW

PULL HANDLE FWD SCAV AIR OUTLET
FLAPPER VALVE
Figure 2. Particle Separator Operating Principle Current Type (APM Unit)

FILTER SCREEN

FILTERED
PLENUM CHAMBER AIR TO

ACCESS (FILTER ENGINE

PULL HANDLE BYPASS) DOOR AIR INLET
NORMALLY CLOSED
SWIRL GUIDES CONTAMINATED AIR
TO SCAVENGE EJECTOR
SWIRL GUIDES
MAINTENANCE MANUAL
SWIRL GUIDES TO ENGINE

AIR INLET
711010
SCAVENGE EJECTOR NOZZLE
EJECTOR MANIFOLD EJECTOR
LOCATED ON BOTTOM MANIFOLD
OF PARTICLE SEPARATOR
FILTER TUBE
(SEE DETAIL VIEW)
ENGINE AIR INLET
AFT FAIRING
AIR
FILTER ATMOSPHERIC AIR
CLOGD FILTERED AIR

INDICATOR CONTAMINATED AIR
LIGHT
SCAV AIR PRESSURE SWITCH ENGINE COMPRESSOR BLEED AIR
AIR
Revision 22
CSPHMI2
(PRESSURE ACTIVATED) MECHANICAL ACTUATION

ENGINE COMPRESSOR BLEED AIR ELECTRICAL ACTUATION
Page 4
AIR BLEED SOLENOID
OFF (SHUTOFF) VALVE
MAINTENANCE MANUAL

FAULT ISOLATION
1. Engine Air Particle Separator Fault
Isolation
Table 101. Engine Air Particle Separator Fault Isolation

Turbine outlet temperature (TOT) Partially blocked particle separator Clean and service particle separator
gage indicates a moderate and, or mist eliminator. installation.
temperature increase with all other
indications normal.
FILTER CLOGGED caution light Clogged filter. Clean and service particle separator
on. Light goes out when air bypass installation.
door is opened.
Filter requires frequent cleaning. Inadequate scavenge air flow; Inspect scavenge air system for
Loads up with SCAV AIR, ON and leaking scavenge air bleed air leakage. Repair system as required.
functioning. lines.
Solenoid air valve blocked. Clean solenoid air valve.
FILTER CLOGGED caution light Lamp failed. Replace lamp.
fails to come on when filter is
Disconnected, open or loose Check continuity, repair or replace
clogged.
wiring. wiring.
Faulty air pressure switch. Replace pressure switch.
FILTER CLOGGED caution light Defective light assembly. Replace light assembly.
stays on regardless of bypass door
Defective air pressure switch. Replace air pressure switch.
position.
Wiring problem. Repair wiring.
FILTER CLOGGED caution light Defective wiring. Repair wiring.
fails to come on when air filter is
clogged but works when tested. Defective air pressure switch. Replace air pressure switch.
FILTER BYPASS CONTROL Disconnected or broken cable. Repair or replace cables.

handle is pulled but bypass door
fails to open.
Air bypass door does not open all Cable stop out of adjustment. Adjust cable stop.
the way when FILTER BYPASS
CONTROL handle is pulled to
forward limit.
FILTER BYPASS CONTROL Defective return spring. Replace return spring.
handle fails to return to full aft
position after control actuation. Cable kinked, worn or binding. Repair or replace cable assembly.
No air is exhausted through outlet Defective wiring. Repair wiring.

duct with SCAV AIR circuit breaker
Disconnected or damaged Connect or replace scavenge air line.
ON and engine running.
scavenge air line.
Defective solenoid air valve. Replace solenoid air valve.
Page 101
711010 Revision 36
MAINTENANCE MANUAL
UTILITY SCAVENGE AIR

P206
CB117 CB15
2 1 1 2 A
P16B20 P16C20 P16D20
LINE LINE 3A LOAD SPLICE (NOTE 3)
DC 369A8462 SCAV. AIR
BUS P17A20N SOLENOID
(NOTE 3)
B
E45
1
P16E22
3 FILTER CLOGGED LIGHT (AMBER)

P16J22
SPLICE AND PRESSTOTEST SWITCH
SPLICE SPLICE SPLICE

P16F22 P16G22 P16H22
P16K22N TB6 AIR

GND PRESSURE E15
SWITCH
GND
NOTES:
1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE
ELECTRICAL SYSTEM WIRING DIAGRAM IN CSPHMI3
FOR COMPLETE CIRCUIT INTERCONNECT AT INSTALLATION.
2. ASTERISK ( * ) INDICATES WIRE IS CUT TO LENGTH AT
INSTALLATION.
3. PART OF WIRE HARNESS 369D24163.
G7110021A
WIRE LIST
WIRE NO. LENGTH FROM TERMINATION TO TERMINATION
P17A20N P206B E45
P16K22N 72.0* SPLICE 32445 TB6 MS25036101
P16J22 10.0 LIGHT 3 SOLDER SPLICE 32445
P16H22 72.0* SPLICE 32445 E15 MS25036103
P16G22 204.0* SPLICE 32445 SPLICE 32445
P16F22 12.0 LIGHT 2 SOLDER SPLICE 32445
P16E22 3.0 CB15 LINE MS25036149 LIGHT 1 SOLDER
P16D20 SPLICE P206A
P16C20 240.0* CB15 LOAD MS25036149 SPLICE 32445
P16B20 72.0* CB117 LINE MS25036149 CB15 LINE MS25036149

Installation Wiring Diagram (SlimLine Panel)
Page 102
Revision 36 711010
MAINTENANCE MANUAL
CB15
TB7003 P618J P9J
1 2 P16A22 NP P16M22 a P16MM22 f P16C20
P16B22 JK P16AA22
TB103 P206
A
SCAVAIR
P16E22
1 SOLENOID B P17D20N E45
E72 M
FILTER
3 P618J P9J
BYPASS P16J22N
LIGHT P16L22 TW P16F22 d P16FF22 k P16G22
2
B
SP207
A
SP206
E15 P16H22N A B
BYPASS
AIR SW
NOTES:
1. APPLICABLE TO 369D MODEL, S/N 1222 AND SUBS. WITH
TPANEL AND CENTER ELECTRICAL CONSOLE.
2. EXISTING WIRING IS SHOWN PHANTOMED. WIRE TO BE
INSTALLED IS SOLID.
G7110022
Figure 102. 369H90148503, 505, 507, 509 Particle Separator Installation

Wiring Diagram (TPanel with Center Console)
Page 103
711010 Revision 36
MAINTENANCE MANUAL
KNIFE SPLICE VARISTOR

(NOTE 2) P206
P16C20 P16D20 A
(NOTE 1) SCAV AIR
SOLENOID
P17A20N B
CB119 E45
WIRE HARNESS
1 2 TERMINAL LUG
(NOTE 4)
(REF)
369H90148101 ALTERNATE CONFIGURATION
SP207 SP206 E15

CB15
P514D20 P16G22 B A A B P16H22N
1 3A 2 P16MA20
(NOTE 1)
AIR PRESSURE SWITCH
P9J
P16F20 f P206
P16M20 q P16C20 A 369A8462
TB5034 (REF) (NOTE 1) SCAV AIR
P17D20N B SOLENOID
E45 VARISTOR
MS3106R10SL4S
(NOTE 2)
SEE ALT. CONF. CONNECTOR
G J
K L M P514C20
P12 (REF) VARISTOR
TB5036 (REF)
CB104 E508A20 V P206 (REF)
L532A20 A B
1 5A 2
B DIMMER A
D B
G J E559A20
SOLDER
SHRINK TUBING CONNECTIONS
P514B20 VARISTOR
TB50312 (REF) INSTALLATION
3 C 2 LIGHT ASSY
(NOTE 3)
4 1
NOTE 1
VIEW LOOKING AT REAR
M531C20 K L M E511BB20
TB5051/2 (REF) NO
E511B20 E15
P514A20
NC C
F A P514G20
LAMP TEST
NOTES:
1. ALL EXISTING WIRES ARE PHANTOMED. WIRES TO BE INSTALLED ARE
IN SOLID LINES.
2. VARISTOR WIRES TO BE AS SHORT AS POSSIBLE.
3. USE 20 GAGE BUSS WIRE AND SHRINK TUBING AS REQUIRED.
4. P16D20 MAY BE TRIMMED TO APPROXIMATELY 16 IN. (41 CM) LENGTH.
G711001A

Installation Wiring Diagram
Page 104
Revision 36 711010
MAINTENANCE MANUAL
CB150
(SCAVAIR)
P/J1203A P1201J P206
1 2
P1008AA22 D10 P1008A22 10 P1008B22 A
3A SCAVAIR
CR201
SOLENOID
B
E18
P1150A22N A F
P527 S2001 P1154C22N
SP207 SP206
AIR FILTER
P P1154A22 11 P1154B22 A B A B
1 BYPASS SW 2
NOTE:
ALTERNATE CONFIGURATION 20 GA JMPR
FOR TPANEL WITH CENTER
CONSOLE.
CB150 P1201J P206

2
(SCAVAIR) 1 P1008A22 10 P1008B22 A
3A SCAVAIR
CR201
SOLENOID
B
E18
P1150A22N A F
S2001 P1154C22N
WARNING SP207 SP206
AIR FILTER
PRESSTOTEST 11 P1154B22 A B A B
1 BYPASS SW 2
E33
NC S1 W1040C22N B 20 GA JMPR
NO
NC S2 P1154A22
NO W1237B22
TB5031/2
W1237A22 F L
W1237C22 E F G H
TB5032 A P1233B22 A B C D TB5038
J K L M G
W1040F22 M
H
B P1233C22
AIR FILTER
J N
CLOGGED LIGHT
K C
2
P 1
D C
R 3
4
E
W1040E22
NOTES:
1. APPLICABLE TO 369E S/N 384 &
SUBS AND 369FF S/N 076 & SUBS.
P12 DIMMER CONTROL UNIT 2. EXISTING WIRING IS SHOWN
PHANTOMED. WIRE TO BE
D WASNING LTS BRT/DIM INSTALLED IS SOLID.
B DC GROUND TEST 3. THIS WIRING DIAGRAM SHOULD
BE USED WITH THE ELECTRICAL
SYSTEM WIRING DIAGRAM IN
CSPHMI3 FOR COMPLETE
IDENTIFICATION.
G7110023
Figure 104. 369H90148535,537, 539, 541, 543, 545 and 500N901481, 3

Particle Separator Installation Wiring Diagram
Page 105
711010 Revision 36
MAINTENANCE MANUAL
Page 106
Revision 36 711010
MAINTENANCE MANUAL

1. Air Bypass Door System Maintenance 2. Solenoid Air Valve Cleaning
Consumable Materials Consumable Materials

(Ref. Section 910000) (Ref. Section 910000)
Item Nomenclature Item Nomenclature
CM106 Fluorocarbon dry lubricant CM112 Antiseize compound high temperature
NOTE: Maintain scavenge air equipment per

CAUTION FAA publication, EAAC43.131A and 2A.
D Prevent engine FOD. Secure a cover over Use antiseize compound

CAUTION (CM112) on all male threaded
the engine intake prior to working inside
plenum chamber. Remove cover after fittings prior to installation.
completing work.
(1). To access solenoid air valve; remove
D Loose, missing or improperly installed air lower and center air duct trim from
bypass door hardware may cause engine forward left side of aft passenger
damage. compartment bulkhead.
NOTE: Maintain door system equipment per NOTE: Solenoid air valve water flush proce-
FAA publication, EAAC43.131A and 2A. dure may be accomplished with valve in-
stalled or removed from helicopter. In either
(1). Disconnect cable from door. case, a 28 Vdc power supply is required to
actuate valve for cleaning.
(2). Inspect and replace loose or worn door
hinge pins with 0.091 inch (2.3114 mm) (2). Connect a low pressure, clean water
diameter corrosion resistant wire. source to valve inlet fitting. Connect a
hose to the outlet fitting to route
(3). Inspect all door hardware for wear, discharged water to a drain. Connect a
corrosion, correct installation, secure 28 Vdc external power source to
attachment and proper operation. helicopter or the valve, as required.
(4). Connect cable to door. (3). Turn on water. Alternately open and
close valve with SCAV AIR circuit
(5). Close door. Check for positive latching breaker switch to flush valve poppet
and correct alignment. Peel or add latch seat.
clip shims to align door flush with (4). Reverse air valve water connections.
fairing surface. Repeat flushing procedure.
(6). Rig air bypass door (Ref. Air Bypass Compressor bleed air is hot
Door Rigging) after replacing either CAUTION enough to char tube identifica-
forward or aft cable, or changing cable tion tapes that may cause FOD. Remove
travel. identification tapes from compressor bleed
air tubes prior to installation.
(7). Spray gasket and door edge with S122
fluorocarbon dry lubricant (CM106) if (5). Install solenoid air valve. Torque valve
operating in temperatures below 40F mounting bolts to 22 27 inch
(4.5C). pounds (2.49 3.05 Nm). Torque tube
(8). Remove engine intake cover. 14.69 Nm).
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711010 Revision 22
MAINTENANCE MANUAL
3. Air Pressure Sensing Switch Maintenance (b). Have an assistant press hard against
the air bypass door in an attempt to
Air pressure switch and AIR FILTER keep the latchbolts from moving up
CLOGGED caution light circuit function may out of their clips.
be quickchecked as follows:
(c). Grasp FILTER BYPASS CONTROL
(1). Open air bypass door. handle and slowly move it forward.
The distance the handle travels
Prevent engine FOD. Secure a before meeting the solid resistance of
CAUTION cover over the engine intake the latchbolts gives an indication of
prior to working inside plenum chamber. cable slack and lost motion due to
Remove cover after completing work. wear.
(4). Remove cable slack as follows:
(2). Attach a suitable length of 3/16 inch
(4.76 mm) ID hose to pressure switch (a). Break lockwire between door latch
nipple. Connect a vacuum source to the center crank threaded swivel fitting
hose. and cable end fitting (Ref.
Figure 201, detail D). Remove
(3). Connect 28 Vdc power to the helicopter. attaching hardware and swivel
fitting from door latch center crank.
(4). Apply vacuum to pressure switch. The Thread swivel fitting up swaged
AIR FILTER CLOGGED caution light cable terminal end 2 3 turns.
should come on. Release the vacuum Reassemble all door hardware except
and the light should go out. lockwire.
(b). Repeat previous steps as required
4. Air Bypass Door Rigging (369D/E/FF) until slack is removed. Do not
preload cable.
Rig air bypass door installation after replacing
forward or aft cables or when door operation or (c). Lockwire cable end fitting to door
opening angle is incorrect. Rig door as follows: latch center crank swivel fitting.
(5). Adjust door opening angle as follows:
Prevent engine FOD. Secure a
CAUTION cover over the engine intake (a). Thread cablestop in or out of stop
prior to working inside plenum chamber. sleeve until top of cablestop is 1.65
Remove cover after completing work. inches (4.19 cm) below cable swaged
ball.
(1). Cycle air bypass door control handle (b). Pull FILTER BYPASS CONTROL
and door mechanism several times to be handle forward until aft cable
certain system does not bind at any swaged ball bottoms in cable stop.
point. Isolate problem and repair a Maintain cable tension to keep cable
binding cable or door latch system ball against stop.
before continuing.
(c). Pull air bypass door outboard to
(2). With door open, make sure FILTER maintain cable tension.
BYPASS CONTROL handle is returned Avoid an erroneous cable adjust-
full aft against cable housing and CAUTION ment. Maintain a constant cable
spring resistance is immediately felt as ball contact with cable stop as stop is ad-
handle is started forward. justed.
(3). Determine if there is excess slack in the (d). Adjust cable stop until air bypass
cable system as follows: door opens to a minimum 45 angle
relative to fairing exterior surface.
(a). Close air bypass door. Try door to Measure angle between door and
make sure latchbolts are bottomed fairing exterior surface at Sta. 136.00
in latchclips. (Ref. Figure 201, details G and H).
Page 202
Revision 22 711010
MAINTENANCE MANUAL
(e). Release FILTER BYPASS CONTROL (2). Cycle air bypass door control handle
handle. Inspect handle for freedom of and door mechanism several times to be
movement, full retraction and contact certain system does not bind at any
with forward fitting. point. Isolate problem and repair a
binding cable or door latch system
(f). Close air bypass door. before continuing.
(g). Check that aft cable is tight and (3). Minor repositioning of the cable
cable swaged ball rests against top of assembly can be performed by loosening
cablestop. the installation hardware to reposition
the cable.
(h). Inspect pulley alignment. All pulleys
must line up within 0.13 inch (3.302 6. Particle Separator Cleaning
mm).
(i). Inspect cable for correct routing Consumable Materials
around pulleys. Rotate each pulley (Ref. Section 910000)
90 to distribute wear. Item Nomenclature
CM226 Cleaning compound, alkaline waterbase
(j). Peel cablestop support bracket
laminated shim as required to center
cable inside cablestop to within (1). Submerge separator in a solution of
0.060 inch (1.524 mm). detergent soap (CM226) and water for
at least 15 minutes. Clean screens and
(k). Torque cablestop jamnut to 10 30 vortex tubes with a soft, longbristle
inchpounds (1.13 3.39 Nm). brush.
(6). Check all components of FILTER (2). Flush with clean water. Drain and blow
BYPASS CONTROL system for correct out ejector nozzle with dry, low pressure
operation. Inspect all fasteners for compressed air.
security.
7. Mist Eliminator Maintenance
5. Air Bypass Door Rigging (500N) (1). Remove mist eliminator and clean with
solvent or steam.
(Ref. Figure 202)
NOTE: Mist eliminator is all stainless steel.
Prevent engine FOD. Secure a The assembly will not be harmed by conven-
CAUTION cover over the engine intake
tional metal cleaning solutions.
prior to working inside plenum chamber.
Remove cover after completing work. (2). Examine plenum chamber. A dust
accumulation indicates leakage which
(1). The bypass door cable length is deter- must be identified and eliminated.
mined on the initial installation.
(3). Spray 15 milliliters of engine oil on
NOTE: The control cable assembly shall actu- each face of the mist eliminator prior to
ate with one pound pull. installation.
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711010 Revision 22
MAINTENANCE MANUAL
UPPER RIGHT PULLEY
ENGINE AIR INLET

AFT FAIRING
RETAINER (2)
DOOR OPERATING AFT
CABLE
CLIP
DOOR OPERATING CABLE CONNECTOR

FORWARD CABLE RETURN SPRING
GROMMET
GROMMET CLAMP
BYPASS AIR CONTROL
RELEASE HANDLE
FORWARD AND AFT CABLE INSTALLATION
PULLEY GUARD
PLATE
AFT FAIRING
BUSHING
AFT FAIRING PULLEY

(NOTE 1)
UPPER PULLEY
BRACKET LOWER PULLEY
BRACKET
BUSHING
LOWER PULLEY INSTALLATION

PULLEY
(NOTE 1)
UPPER PULLEY INSTALLATION (TYPICAL)
G7110031
Figure 201. Air Bypass Door System (369D/E/FF) (Sheet 1 of 3)
Page 204
Revision 22 711010
MAINTENANCE MANUAL
CABLE
CLIP
LINK
GASKET
CENTER
CRANK LATCH ASSY
LAMINATED SHIM
(NOTE 3)
CLIP
FILTER BYPASS DOOR INSTALLATION
WASHER WASHER
BOLT
AFT FAIRING
CABLE STOP
NUT
(NOTE 2)
CABLE STOP
SLEEVE
TYPICAL LINKAGE INSTALLATION
(4 PLACES)
CABLE STOP
BRACKET
NOTES: SHIM
1. PULLEYS TO BE IN ALIGNMENT WITHIN 0.13 IN. (3.302 MM). (NOTE 4)
2. TIGHTEN NUT TO GET 0.0050.015 IN. (0.1270.381 MM) GAP BETWEEN
SLEEVE NUT
BOLT HEAD AND WASHER; 4 PLACES.
3. ADJUST LAMINATED SHIM THICKNESS TO GET CORRECT DOOR
CABLE STOP JAMNUT
LATCHING AND ALIGNMENT.
4. SHIM TO ALIGN CABLE WITH CABLE STOP WITHIN 0.060 IN. (1.524 MM). CABLE STOP INSTALLATION G7110032B
Page 205
711010 Revision 22
MAINTENANCE MANUAL
DOOR SWAGED BALL

LATCHED
1.65 IN. (4.191 CM)

CABLE TRAVEL
CABLE STOP
DOOR
OPEN
CABLE STOP JAMNUT

QUICKDISCONNECT
DOOR STOP ADJUSTMENT
COTTER PIN
MINIMUM DOOR
OPENING
45
VIEW
369A84423 LATCH ASSEMBLY
G7110033B
Page 206
Revision 22 711010
MAINTENANCE MANUAL
GROMMET
GROMMET
ENGINE INLET
BYPASS DOOR
LATCH ASSY
BYPASS DOOR
CLIP
BYPASS AIR CONTROL

RELEASE HANDLE
HINGE
LINK
PIVOT
CABLE ASSY FITTING
BRACKET
G711024
Figure 202. Air Bypass Door System (500N)

711010 Revision 22
MAINTENANCE MANUAL

1. PLM Particle Separator Replacement (14). Disconnect and remove ejector scavenge
air line between particle separator and
A. PLM Particle Separator Removal bracket mounted elbow.
(1). Remove forward engine air inlet (15). If installed, remove mist eliminator.
fairings.
(16). Unbolt, then tilt top of particle separa-
(2). Pull FILTER BYPASS CONTROL tor forward and remove from fairing.
handle to open filter bypass door. B. PLM Particle Separator Installation
Prevent engine FOD. Secure a Install particle separator in reverse order of
CAUTION cover over the engine intake removal and per the following procedures:
Remove cover after completing work. Consumable Materials
(3). Remove engine air cooling inlet screen. (Ref. Section 910000)
Item Nomenclature
(4). In crew compartment; remove map case CM112 Antiseize compound high temperature
trim panel from control channel (Ref.
Chap. 25).
(1). Center and clamp tail rotor control
(5). Disconnect forward cable from aft cable pedals in neutral position. Install
at quickdisconnect fitting. Remove forward boot on tail rotor pitch control
spring retainers and spring. rod. Adjust boot free length between
7.13 and 7.22 inches (18.1102 and
(6). Remove handle plug button. Separate 18.3388 cm). Install tyrap.
retainers and remove handle.
(2). Use the same number of washers under
(7). Remove attaching hardware and cable forward cable fitting as were removed.
retaining clamps. Remove cable forward Washer stack height variances will
fitting nut and washers. affect door rigging.
(8). Pull cable assembly forward into crew Use antiseize compound on all
CAUTION male threaded fittings prior to
compartment far enough to clear
particle separator. installation.
(3). Apply antiseize compound (CM112) to
(9). Disconnect and remove pressure switch
fitting threads and particle separator
tubes, jamnut, washers and union.
attaching hardware.
(10). Remove particle separator fairing (4). Check air bypass door rig (Ref. Air
retaining screws and washers. Bypass Door Rigging).
NOTE: Left fairing installations without re- (5). Perform an operational check of air
movable lower cover require the tail rotor bypass door and scavenge air systems
control rod be disconnected at Sta. 95.00 (Ref. Scavenge Air Operational Check).
bellcrank to remove fairing from helicopter.
2. PLM Scavenge Ejector Replacement
(11). Remove tail rotor control rod boot A. PLM Scavenge Ejector Removal
forward clamp.
(1). Remove lockwire and unbolt ejector
(12). Slide boot and left fairing forward and assembly support bracket.
clear of particle separator.
(2). Remove lockwire and bolts attaching
(13). Unfasten and remove ejector duct ejector assembly hold down plates to
assembly. particle separator ejector box.
Page 401
711010 Revision 22
MAINTENANCE MANUAL
(3). Remove ejector assembly. B. Helicopters Without Mist Eliminator

Access Panel
B. PLM Scavenge Ejector Installation
Prevent engine FOD. Secure a
CAUTION cover over the engine intake
(1). Install ejector in reverse order of
removal. prior to working inside plenum chamber.
Remove cover after completing work.
3. PLM Ejector Nozzle and Manifold (1). Pull FILTER BYPASS CONTROL
Replacement handle to open air bypass door.
(1). Remove ejector assembly (Ref. PLM (2). On 500N installation, remove the fan
Scavenge Ejector Removal). inlet screen and engine plenum access
fairing attachment hardware. Proceed
(2). Remove lockwire and two nuts securing with step (5).
nozzle and manifold assembly to
particle separator ejector box. (3). Remove four screws securing door hinge
upper halves to inlet fairing (Ref.
(3). Remove nozzle and manifold assembly. Figure 201, detail D).
(4). Clean mating surfaces between ejector NOTE: Do not disturb established cable length.
box and nozzle and manifold assembly. (4). Remove cotter pin, nut and washer
from cable endfitting. Remove cable
(5). Install nozzle and manifold assembly in from door. Remove door.
reverse order of removal.
Nine mount bolts are retained
(6). Install ejector assembly. CAUTION in mist eliminator frame. Do not
attempt to remove bolts from frame.
4. Mist Eliminator Replacement
(5). Unbolt mist eliminator from particle
A. Helicopters With Mist Eliminator Access separator.
Panel (6). Pull mist eliminator aft to clear particle
separator frame. Tilt mist eliminator
CAUTION lower edge up and remove unit through
bypass door opening.
D Prevent engine FOD. Secure a cover over
the engine intake prior to working inside C. Mist Eliminator Installation
plenum chamber. Remove cover after (1). Install mist eliminator in reverse order
completing work. of removal.
D If mist eliminator is NOT to be rein-
stalled, remove 4504 tape from particle 5. Donaldson Particle Separator
separator. If not removed, tape may come Replacement
loose and be ingested by the engine. A. Donaldson Particle Separator Removal
NOTE: Mist eliminator access panel installa- (1). Remove engine air inlet forward
tion replaces nine mist eliminator mount fairings.
bolts with a system of permanently installed
(2). Pull FILTER BYPASS CONTROL
clips to secure mist eliminator.
handle to open the air bypass door (Ref.
(1). On top of aft inlet fairing; unfasten two Figure 201, detail A).
1/4turn panel fasteners. Lift panel Prevent engine FOD. Secure a
trailing edge, then entire panel clear of CAUTION cover over the engine intake
access opening. prior to working inside plenum chamber.
Remove cover after completing work.
(2). Lift mist eliminator out of access panel
opening. (3). Remove engine air cooling inlet screen.
Page 402
Revision 37 711010
MAINTENANCE MANUAL
(4). In crew compartment; remove map case (15). Remove exit port screen attaching
trim panel from control channel (Ref. hardware and duct.
Chap. 25).
B. Donaldson Particle Separator Installation
(5). Disconnect forward cable from aft cable
at quickdisconnect fitting. Remove Install particle separator assembly in reverse
handle plug button. Separate retainers order of removal and as follows:
and remove handle.
(6). Remove spring retainers and spring. (Ref. Section 910000)
Item Nomenclature
(7). Remove attaching hardware and cable
retaining clamps. Remove cable forward CM112 Antiseize compound high temperature
fitting nut and washers. Pull cable
assembly into crew compartment. NOTE: Apply antiseize compound (CM112) to
(8). Remove pressure switch tubes and male threads of fittings, nozzle manifold
union. bolts and particle separator attaching hard-
ware before installation.
NOTE: It is not necessary to disconnect tail ro- (1). Bench assemble rubber sleeve and
tor control rod to remove left fairing if fair-
Oring on grooved end of ejector.
ing is equipped with a removable cover.
(2). Align nozzle manifold and ejector inside
(9). Disconnect forward end of tail rotor aft fairing.
control rod at Sta. 95.00 bellcrank.
(3). Position ejector so that top flapper
(10). Remove fairing retaining screws and valve vertical hinge line angle is 10 to
washers. Remove tail rotor control rod 20 degrees counterclockwise from
boot forward. ejector vertical centerline.
clamp. Slide left fairing forward on tail rotor (4). Torque ejector and nozzle manifold
control rod to clear particle separator. bolts to 12 15 inchpounds (1.36
1.69 Nm).
NOTE: Paint an alignment mark across ejector
and nozzle manifold flanges prior to disas- (5). Install tail rotor control rod forward
sembly as a reference for later assembly. boot with a free length of 7.13 to 7.22
inches (18.1102 and 18.3388 cm) with
(11). Remove bolts and washers securing tail rotor pedals centered.
nozzle manifold to particle separator.
(6). Use the same number of washers under
(12). Unbolt particle separator. Tilt top of forward cable fitting as were removed.
particle separator forward and remove Hardware position changes or washer
from fairing. stack height variances will affect door
rigging.
(13). Disconnect upper air tube assembly
from nozzle manifold. Move forward (7). Rig air bypass door (Ref. Air Bypass
Oring from ejector to rubber sleeve. Door Rigging).
Remove nozzle manifold and ejector
from aft fairing. (8). Perform air bypass door and scavenge
air system operational checks (Ref.
(14). Remove sleeve and Orings from duct. Scavenge Air Operational Check).

711010 Revision 22
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Engine Air Inlet Bypass Door 300Hour (c). The latch engagement faying surface,
Inspection where it contacts the plenum, is worn
more than 0.050 inch (1.270 mm)
(Ref. Figure 201) below the original surface.
(5). Inspect door hinges for wear and hinge
Consumable Materials fastening hardware for security. Repair
(Ref. Section 910000) or replace hinges as required.
Item Nomenclature (6). Inspect door for worn or damaged
CM425 Sealing compound latching and attachment hardware.
(7). Check insert assembly and latch
linkages for wear and lost motion.
Prevent engine FOD. Secure a Repair or replace latch hardware as
CAUTION cover over the engine intake required.
(8). Inspect door system cable and cable
Use extreme care when working around en-
ends for corrosion, fraying, chaffing and
gine inlet to prevent any foreign object from
freedom of movement.
entering engine. Remove cover after com-
pleting work. (9). Inspect door system cable pulleys,
pulley bushings and brackets for wear,
NOTE: Inspect Engine Air Inlet Bypass Door damage, freedom of movement and
per FAA publication, EAAC43.131B. security.
(10). Reinstall engine inlet bypass door. Seal
(1). Remove engine inlet bypass door and all cotter pins with sealant (CM425).
inspect air bypass door gasket seal for
condition and secure attachment. No (11). Inspect door for proper alignment when
gasket seal deterioration or debonding closed. Door must fit snug against seal
allowed. Replace door gasket as with obvious seal compression.
required. (12). Inspect latches for positive latching.
(13). Pull FILTER BYPASS CONTROL
(2). Inspect door surfaces for cracking,
handle. Action to be a smooth, positive
chaffing or damage. Repair door per
door opening with no binding. Release
Structural Repair Manual (CSP
handle. Handle should snap back to
SRM6).
stowed position.
(3). Remove and replace the latch retention 2. PLM Particle Separator Inspection
cotter pin (located inside the attach
(1). Inspect vortex generator tubes for
cable U clamp). Seal cotter pin with
broken, loose or missing vanes and
sealant (CM425).
center pins.
(4). Replace latch assembly if: (2). Inspect outlet tube for security and
damage.
(a). The cotter pin hole in the latch stem (3). Inspect inlet plate for dents punctures
is elongated more than 0.080 inch and cracks.
(2.032 mm).
(4). Inspect vortex tube particle discharge
(b). The cotter pin has worn into the openings for clogging.
surface of the cable attach U clip, (5). Inspect separator and mist eliminator
more than 1/2 the thickness of the mounting seals for secure attachment
clip, 0.025 inch (0.635 mm) deep. and damage. Replace damaged seals.
Page 601
711010 Revision 39
MAINTENANCE MANUAL
Left fairing inspection and re- (4). Inspect gasket tapes for deterioration
CAUTION work or replacement is manda- and security. Replace damaged gasket
tory for particle separator installations, part tapes.
numbers 369H90148507, and 509. Early
installations were fitted with left forward (5). Inspect entire particle separator
fairings, PN 369D29012811 equipped with assembly for cracks, holes and distor-
a single screw and nutplate securing a re- tion. Cracks may indicate filter preload,
movable fairing section, PN misalignment or distortion when
369D29012831 over the tail rotor control installed. Align filter (Ref. Particle
rod. Separator Alignment and Joint Surface
Repair).
(6). Inspect tail rotor control rod for (6). Inspect rubber sleeves for cuts, holes or
abrasion or gouging caused by contact deterioration.
with particle separator fairing or
fairing hardware. Modify, repair or (7). Inspect Orings for nicks, cuts, wear or
replace fairing (Ref Fairing Modifica- deterioration.
tion (369D Only)). Inspect, repair or
(8). Inspect ejector tube for cuts, breaks or
replace control rod if damaged beyond
distortion.
limits (Ref. Sec. 672010).
(9). Inspect flapper valve for condition and
(7). Inspect ejector flapper valve and hinge free movement.
for wear and corrosion. Repair or
replace valve parts as required. NOTE: Ejectors with a missing flapper valve
may be continued in operation until a re-
(8). Inspect ejector tubes for cuts, breaks placement is installed.
and distortion. Inspect flange condition. (10). Inspect nozzle manifold for cracks and
distortion.
(9). Inspect tube nuts and fittings for
crossed or stripped threads. (11). Inspect fitting for crossed or stripped
threads. See that the seven nozzle air
(10). Inspect scavenge air discharge duct for passages are open, clean and undam-
damage. aged.
(11). Inspect entire assembly for cracks, (12). Inspect ejector exhaust duct screen for
holes and distortion. Cracks may damage or clogging.
indicate that assembly is subject to 4. Scavenge Air Operational Check
distortion loads when installed.
Engine operation or helicop-
3. Donaldson Particle Separator Inspection WARNING ter flight must be accom-
plished in accordance with require-
(1). Inspect filter inlet screens for damage ments and limitations specified in the
and secure attachment. Remove Pilots Flight Manual and applicable
damaged inlet screens. supplements.
(1). Ensure air bypass door is closed.
NOTE: Particle separator may be operated
without inlet screens. (2). Ground run engine per Pilots Flight
Manual.
(2). Inspect vortex tubes for for security and
broken or missing vanes. (3). Switch SCAV AIR circuit breaker ON.
NOTE: A slight increase in turbine outlet tem-
NOTE: Up to five damaged vortex tubes may be perature (TOT) is normal when SCAV AIR
blocked off with patches. circuit breaker is switched ON.
(3). Inspect vortex tube particle separator (4). Have an assistant check for scavenge
openings for clogging. air exhaust from outlet duct. Airflow
Page 602
Revision 22 711010
MAINTENANCE MANUAL
from duct indicates that solenoid air the tube relative to the switch closing
valve has opened. point. The total of the differential
heights of both legs of the utube is
(5). Switch SCAV AIR circuit breaker OFF. equal to switch actuation pressure.
(6). Check that no scavenge air flows from (6). Switch closing pressures shall be per
outlet duct. the applicable particle separator
(7). Shut down engine per Pilots Flight installation dash number shown (Ref.
Manual. Figure 601).
5. Air Pressure Sensing Switch Calibration 6. Mist Eliminator Inspection

Check (1). Check mist eliminator serial number
(1). Assemble test equipment (Ref. for APM serial numbers 005 thru 069.
Figure 601). Remove the wire staples from a mist
eliminator so identified.
(2). Attach pressure switch to test equip-
ment. Connect a suitable vacuum (2). Inspect frame and screens for security
source to pressure switch nipple and and condition. Replace mist eliminator
utube. if screens are partially detached, or
assembly distortion prevents joint seal
(3). Connect an ohmmeter or continuity contact with the particle separator.
tester to pressure switch electrical
leads. (3). Inspect all nine bolts, where installed,
for security in mist eliminator frame.
(4). Cycle switch from open to close several Repair or replace bolts as required (Ref.
times with vacuum. Watch meter for Page 803).
indication of switch closure. Release
vacuum. (4). Examine outlet side of mist eliminator.
Surface should be slightly oily but
(5). Slowly apply vacuum. Note utube clean. Dirt on the outlet side signals the
water height differential in both legs of need to clean the assembly.
Page 603
711010 Revision 22
MAINTENANCE MANUAL
TO L.H. FAIRING
ATTACHING UNION
SUCTION SOURCE
HOSE TEE
POWER LEAD
RETURN LEAD
24 IN (61 CM)
SCALE
OHMMETER OR
CONTINUITY
TESTER
24 IN (61 CM)
STRAIGHT
SECTION
12 IN (30.5 CM)
H2O STATIC
HEIGHT
369A8402 OPEN CLOSE
15 2.0 12.500.25
TYGON TUBING (OR EQUIVALENT)
13 2.0 18.500.25 BENT AND FILLED WITH H2O TO
STATIC HEIGHT AS SHOWN
7 2.0 10.500.25
3 2.0 4.80.4
G711004E
Figure 601. Air Pressure Sensing Switch Calibration Check
Page 604
Revision 38 711010
MAINTENANCE MANUAL

REPAIRS
1. PLM Particle Separator Repairs Permanent repairs or particle
CAUTION separator replacement should
be accomplished as soon as possible. Do not
use repair kit if mounting plate holes are en-
larged or distorted so as to prevent the re-
Item Nomenclature
pair plug snaplock lip from fully engaging
plate hole edge.
(a). Repair plugs, AA9500D929 are
CM728 Tape, pressure sensitive used to seal pushedin but otherwise
undamaged vortex generator tubes.
(b). Stems, AA9500D930 are used with
NOTE: repair plugs to seal the vortex
generator tube hole when the the
D The following particle separator repair/ tube is missing or removed.
replacement items and, or kits are avail-
(c). Stems, AA9500D931 are used with
able from Pall Land Marine (PLM) or
repair plugs when both the vortex
through your local distributor (Ref. Sec.
generator tube and outlet tube are
010000).
missing or removed.
D AAA2241D1KF1 Repair kit, Centrisep No more than 30 of the 292
scavenge ejector Assy. (Ejector, two plate WARNING vortex generator tubes may
halves, four bolts). be plugged. Plugged tubes shall be
widely distributed over particle sepa-
D AA224A1D1KF2 Repair kit, Centrisep rator. Not more than 15 plugged tubes
nozzle and manifold Assy. may be concentrated in any one area.
B. Displaced Vortex Generator Tube
The following procedures are for
CAUTION Pall Land Marine (PLM) par- (Ref. Figure 801)
ticle separators only. (1). Inspect displaced vortex generator tube
for missing center pin and extensive
rim damage. Should either condition
A. Vortex Tube Plug Installation exist, refer to Damaged Or Missing
Vortex Generator Tube.
NOTE: Procedures are per Pall Land Marine (2). Position particle separator on a table
Corporation publication, PLMTM801. with front surface of vortex tube plate
Contact PLM direct for additional informa- up.
tion. A vortex generator tube replacement
kit may be available that will supersede use (3). Press damaged tube assembly all the
of Tube Repair Kit AA81011KF1 required way in. Ensure that vortex tube
to accomplish the following temporary re- bottoms on outlet tube per illustration
pairs. (Ref. Figure 801, view B).
(4). Insert repair plug AA9500D929 in
the hole. Align plug with vortex
(1). The AA81011KF1 repair kit contain generator center pin.
parts required to plug holes created by
displacement of, or damage to, the (5). Press plug into inlet tube plate until
vortex generator and outlet tubes. plug snaps in place.
Page 801
711010 Revision 22
MAINTENANCE MANUAL
INLET TUBE INLET TUBE REPAIR PLUG

PLATE PLATE AA9500D929
VORTEX GENERATOR
TUBE
OUTLET TUBE
OUTLET TUBE
PLATE OUTLET TUBE OUTLET TUBE
PLATE
A. SERVICEABLE INSTALLATION B. DISPLACE VORTEX GENERATOR

TUBE REPAIR
INLET TUBE REPAIR PLUG

REPAIR PLUG INLET TUBE
PLATE AA9500D929
AA9500D929 PLATE
STEM
AA9500D930
STEM
OUTLET TUBE AA9500D931
OUTLET TUBE
PLATE
OUTLET TUBE PLATE
C. MISSING VOTEX GENERATOR D. MISSING VORTEX GENERATOR

TUBE REPAIR AND OUTLET TUBE REPAIR
G711005
Figure 801. Vortex Generator Repairs
Page 802
Revision 22 711010
MAINTENANCE MANUAL
C. Damaged Or Missing Vortex Generator F. Fairing Modifications (369D Only)

Tube
(1). Remove remaining vortex generator Consumable Materials
tube material without damaging plate (Ref. Section 910000)
hole. Item Nomenclature
CM501 Fiberglass cloth
(2). Insert center pin of stem
AA9500D930 into plug CM505 Polyester laminating resin
AA9500D929 and install in hole per
illustration (Ref. Figure 801, view C).
Ensure stem free end is inside outlet NOTE: Modification procedures apply to 500D
tube. series helicopters equipped with
369H90148507 or 509 particle separator
(3). Press plug into hole until it snaps in installations and APM (now PLM) particle
place. separators. Early installations were fitted
with left forward fairings, PN
D. Damaged Or Missing Vortex Generator 369D29012811 equipped with a single
and Outlet Tubes screw and nutplate securing a removable
fairing section, PN 369D29012831 over the
(1). Remove remaining vortex generator tail rotor control rod. Modify the 11 and
and outlet tube material. Do not 31 fairing components as follows.
damage either plate hole.
(1). Remove fairings (Ref. PLM Particle
(2). Insert center pin of stem
Separator Removal).
AA9500D931 into plug
AA9500D929 and install in hole per (2). Drill out rivets and remove nutplate
illustration (Ref. Figure 801, view D). from 369D29012811 left fairing
Ensure stem free end protrudes from assembly (Ref. Figure 802, detail A).
outlet tube plate.
(3). Press plug into hole until it snaps in (3). Patch nutplate rivet and screw holes
place. with fiberglass cloth (CM501) and resin
(CM505) per structural repair manual
E. PLM Particle Separator Gasket (SRM).
Replacement
NOTE: A replacement cover, PN
(1). Remove old gasket and clean joint 369D29012851 may be installed in lieu of
surfaces with PD680 dry cleaning reworking 369D29012831 cover assembly.
solvent (CM234) on a clean cloth.
(4). Rework cover, PN 369D29012831 per
(2). Cut 1/8 inch (3.175 mm) thick pressure illustration using fiberglass cloth and
sensitive tape (CM728) to 3/8 inch resin. Laminate one layer of fiberglass
(9.525 mm) width. cloth on top of cover and two layers on
bottom surface (Ref. Figure 802, detail
NOTE: B).
D Note that the particle separator/aft inlet
fairing seal tape is not installed on the (5). Drill two 0.250 inch (6.35 mm) diameter
bottom. screw holes through cover to match
D The inner seal tape is the mist eliminator holes in PN 369D29012811 fairing
joint seal. assembly.
(3). Cut tape to length, peel off backing and (6). Install 369D29012855 and 57 seals
apply to surface. on cover.
(4). Ensure gasket tape is firmly attached (7). Install reworked fairings (Ref. PLM
to surface. Particle Separator Installation).
Page 803
711010 Revision 22
MAINTENANCE MANUAL
SCREW, WASHER NUTPLATE

(REMOVED) (REMOVED)
NOTE 1
1.40 IN. RIVETS
(35.56 MM) FAIRING (REMOVED)
0.60 IN. A MODIFICATIONS
(1.524 MM)
31 COVER
(BEFORE REWORK)
0.80 IN.
(20.32 MM) 57 SEAL EXISTING 39 SEAL
(REMOVED)
55 SEAL
BUILDUP
(NOTE 2)
NOTE 1 A
2.40 IN.
(60.96 MM)
0.61 IN.
(15.494 MM)
ONE LAYER
181 FIBERGLASS 31 COVER
55 SEAL (TOP) (TYP)
COVER MODIFICATION
55 SEAL 41 SEAL
TWO LAYERS 57 SEAL
181 FIBERGLASS VIEW AA
NOTES: (BOTTOM) (TYP)
1. DRILL 0.250 IN (6.35 MM) DIAMETER HOLES IN
COVER TO MATCH 11 FAIRING.
2. SHADED AREA DENOTES FIBERGLASS BUILDUP.
G711019A
Figure 802. Fairing Modifications
Page 804
Revision 22 711010
MAINTENANCE MANUAL
2. Mist Eliminator Repair (3). Using a 0.030 inch (0.762 mm) feeler
gage, check for gaps at the three
(1). The mist eliminator is a nonrepairable mounting bolt attach points. Install
all welded assembly except for the shims in areas where gaps exceed 0.030
mounting bolts required for some inch (0.762 mm) width per the next
installations. Repairs are limited to bolt step.
repair or replacement.
(4). Bond an aluminum or fiberglass shim
NOTE: thickness to the fairing that is equiva-
D The following mist eliminator repair/re- lent to the gap.
placement items and, or kits are available (a). Bond aluminum shims to the fairing
from Pall Land Marine (PLM) or through with epoxy resin (CM504).
your local distributor.
(b). Laminate and bond fiberglass cloth
D AEA2241D2 Mist eliminator Assy.,
per Structural Repair Manual
complete.
procedures (CSPDEF6).
D AAA2241D2KF1 Repair kit, mist elimi-
nator (nine mounting bolts). 4. Donaldson Particle Separator Repair
(369D Only)
(2). Remove mist eliminator assembly per
Mist Eliminator Replacement.
(3). Chase mounting bolt threads with a (Ref. Section 910000)
1032 die, as required. Item Nomenclature
(4). Remove mounting bolts from mist CM503 Fiberglass repair kit
eliminator frame by pulling bolt aft
while unscrewing.
(5). Replace mounting bolts. NOTE: Particle separator repairs are accom-
(6). Flatten an area 0.1600.170 inch plished per standard fiberglass repair meth-
(4.0644.318 mm) wide by 0.125 inch ods using fiberglass repair kit (CM503). En-
(3.175 mm) long, maximum, across the sure that no potential for engine foreign
first three to four threads adjacent to object damage occurs as a result of filter re-
the bolt shank to inhibit removal. pair.
(1). Rebond loose or missing fiberglass
3. Particle Separator Alignment and Joint attachment spacers.
Surface Repair (369D/E/FF)
(2). Rebond front and back wall to center
section seams as required.
(Ref. Section 910000) (3). Rebond manifold nozzle attachment
Item Nomenclature tube.
CM504 Epoxy resin with catalyst (4). Patch repair or fill any other damaged
or cracked areas.
(1). Draw an outline of the particle separa- (5). Replace damaged vortex tubes.
tor on smooth, parallel surfaced, 1/2
inch (12.7 mm) thick phenolic or close NOTE: Up to five damaged vortex tubes may be
grained plywood. Cut template from temporarily blocked.
material. Drill mounting bolt holes. (6). Install not more than five aluminum
patches over vortex tube outlet holes.
(2). Position template against engine air
Install patches with at least three
inlet fairingtofilter mounting surface
mechanically expanded rivets.
and install three bolts and nuts finger
tight. Ensure template is secure and (7). Replace worn or loose gasket tapes as
undistorted. follows:
Page 805
711010 Revision 22
MAINTENANCE MANUAL
MOUNTING
STRUCTURE
AFT AIR INLET

FAIRING
SCREEN
(TYPICAL)
PARTICLE
SEPARATOR
GASKET
(NOTE)
PARTICLE SEPARATOR
NOTE:
INSTALL GASKET AS SHOWN ON AFT FACE
OF PARTICLE SEPARATOR
G711017
Figure 803. Donaldson Particle Separator Gasket Replacement
Page 806
Revision 22 711010
MAINTENANCE MANUAL
MIST ELIMINATOR
ROTATED 180
SECTIONAL VIEW
FLATTENED THREADS
(NOTE)
0.1600.170 IN.
(4.0644.318 MM)
NOTE:
FLATTEN THREADS TO DIMENSION SHOWN.
DO NOT EXCEED MAXIMUM DIMENSION.
0.125 IN. MAX.

DETAIL
(3.175 MM) G711018A
Figure 804. Mist Eliminator Bolt Repair
Page 807
711010 Revision 22
MAINTENANCE MANUAL
(a). Remove tape debris. Wipe tape NOTE:

contact surfaces with a clean cloth D Installation of sealed fairings around the
and PD680 drycleaning solvent particle separator to protect the engine
(CM234). from FOD is required for early Donaldson
particle separator installations
(b). Cut tape 0.380 inch (9.652 mm) wide 369H90148503 and 505 used on some
from 0.125 inch (3.175 mm) thick 369D series helicopters.
Y3192B material (CM728). D Donaldson particle separator installa-
tions are identified by the scavenge air ex-
haust port on the left side of the aft inlet
(c). Install tape across the top and down fairing.
right and left sides of the fairing
D Procedures cover fairing kit,
contact area. Do not apply seal tape
PN369D290140 and pressure switch,
across the bottom (Ref. Figure 803).
PN369A84027 installation.
Install particle separator.
D PN369A84023 pressure switch modifi-
cations to 7 specifications using a Jensen
(8). Perform particle separator alignment #800174 kit are provided. Modification
procedures and the following steps. of a 3 switch to a 7, or procurement and
installation of a 7 switch is mandatory
when auxiliary fairings are installed.
(a). Remove ejectortooutlet duct rubber
sleeve. Use a straight edge to check (1). Remove air inlet forward fairings.
for misalignment between the ejector
and outlet duct. Maximum allowed (2). Remove particle separator (Ref.
misalignment is 1/4 inch (6.35 mm). Donaldson Particle Separator Remov-
al).
(b). Install tapered shims between duct (3). Clean particle separator (Ref. Particle
and screen rubber rim to repair Separator Cleaning).
ejectortooutlet duct misalignment. (4). Inspect particle separator (Ref. Donald-
Use at least two attachment screws son Particle Separator Inspection).
to retain shim.
(5). Repair unit (Ref. Donaldson Particle
Separator Repair).
NOTE: Existing screen and duct attachment
screws are long enough to allow addition of NOTE: 369D2901405 and 7 supports and
1/4 inch (6.35 mm) thick shim. 369D29014011 and 12 fairing assemblies
may be manufactured using drawings pro-
vided (Ref. Figure 806). Apply a coat of
(9). Install particle separator. primer (CM318) after making the parts.
(6). Install LH fairings and seals as follows:
5. Donaldson Particle Separator Auxiliary (a). Locate 369D2901405 seal support
Fairings and Seals Installation forward of aft fairing filter mounting
frame as indicated (Ref. Figure 805,
detail A and section BB).
(b). Use 5 support as a guide and drill
two rivet holes through fairing.
Item Nomenclature
(c). Install support with two
NAS1738B42 rivets.
CM318 Primer
(d). Install 369D29014013 and 25 seals
CM430 Sealant, solvent resistant on support (Ref. Figure 805, view
AA and section BB).
Page 808
Revision 22 711010
MAINTENANCE MANUAL
(e). Position and mark 369D29014011 (h). Install 369D29014017 and 23 seals
fairing (Ref. Figure 805, view EE). on underside of 369H9015141
Drill 0.250 inch (6.35 mm) diameter fairing. Trim 23 seal to match
hole through 11 to match inlet fairing contour (Ref. Figure 805, view
fairing existing nutplate. AA).
(f). Split grommet and install on wire (8). Disconnect and remove 369A84023
and controls bundle (Ref. Figure 805, pressure switch.
view EE). Slip 11 fairing into
grommet groove. (a). Remove screws and separate switch
halves. Remove diaphragmmagnet
(g). Trial fit 369D29014011 fairing on and return spring (Ref. Figure 807).
aft inlet fairing with washer and
screw. Remove fairing assembly. (b). Clean parts with PD680 dry
cleaning solvent (CM234).
(h). Install 369D29014017, 19 and 23
seals on underside of 369H9015131 (c). Reassemble switch with new diaph-
fairing. Trim 19 and 23 seals to ragmmagnet and return spring per
match fairing contour (Ref. illustration.
Figure 805, view AA).
(d). Align screw holes, magnetdiaph-
(7). Install RH fairings and seals as follows: ragm, spring and switch halves and
assemble unit with screws. Lockwire
(a). Locate 369D2901407 seal support screws.
forward of aft fairing filter mounting
frame as indicated (Ref. Figure 805, (e). Install new name plate over existing
view AA and section CC). name plate.
(b). Use 5 support as a guide and drill (9). Check pressure switch operation (Ref.
three rivet holes through fairing. Air Pressure Sensing Switch Calibra-
tion Check). Switch closing should occur
(c). Install support with three between 10.2510.75 inches
NAS1738B42 rivets. (26.03527.305 cm) of water.
(d). Install 369D29014015 seal on (10). Install pressure switch.
support (Ref. Figure 805, view AA
and section CC). (11). Install particle separator (Ref. Donald-
son Particle Separator Installation).
(e). Position and mark 369D29014012
fairing (Ref. Figure 805, view EE). (a). Install 369H9015131 and 41
Drill 0.250 inch (6.35 mm) diameter fairing halves with washers and
hole through 11 to match inlet screws (Ref. Figure 805, view AA).
fairing existing nutplate.
(b). Install 369D29014011 and 12
(f). Split grommet and install on wire fairings with washers and screws
and controls bundle (Ref. Figure 805, (Ref. Figure 805, view EE).
view EE). Slip 12 fairing into
grommet groove. (c). Apply sealing compound, RTV732
(CM430) around all gaps between 11
(g). Trial fit 369D29014012 fairing on and 12 fairings, grommets, wire
aft inlet fairing with washer and bundles, aft fairing and mast fitting
screw. Remove fairing assembly. (Ref. Figure 805, detail A).
Page 809
711010 Revision 22
MAINTENANCE MANUAL
12 FAIRING ASSY
TRIM 12 FAIRING AS REQUIRED TO CLEAR
A EXISTING STRUCTURE IN 369A3053
TYP. FOR INSTL. OF 11 FAIRING
A
17 SEAL
23 SEAL D D
369H9015141 C
MOUNTING FRAME FOR

369H90152 FILTER AT
STA. 124.00
TRIM 19 AND 23 SEALS B

TO MATCH CONTOURS
OF 369H90151 FAIRINGS
W.L. 67.00
3.31 IN. B.L. 865 RN
(8.4074 CM) 369H9015131 B STA.
FAIRING 124.00
369A3053
FAIRING
SEE DETAIL A
11 FAIRING ASSY
NAS1738842 RIVET 15 SEAL 17 SEAL
(3 REQD)
VIEW A A
DRILL 369A3053 TO 7 SUPPORT
MATCH HOLES IN SEAL ALL OPENINGS OR
SUPPORT SECTION C C GAPS USING SILASTIC
ROTATED 90 CCW NO. 732 OR EQUIV.
11 FAIRING ASSY
MOUNTING FRAME FOR
369H90152 FILTER AT
STA. 124.00
W.L. 68.36 13 SEAL

E
B.L. 8.70 LH
25 SEAL
5 SUPPORT 1.25 IN.

(3.175 CM) APPLY SILASTIC NO. 732 OR
EQUIV. BETWEEN FLANGE E 0.19 IN.
(4.826 MM)
OF FAIRING AND 369H3003 SEAL ALL OPENINGS OR
NAS1738842 RIVET GAPS USING SILASTIC
(3 REQD) NO. 732 OR EQUIV. STA.
DRILL 369A3053 TO MATCH 124.00
HOLES IN SUPPORT
SECTION B B DETAIL A
ROTATED 90 CCW TYP. FOR INSTAL. OF 12 FAIRING
G7110141A
Figure 805. Auxiliary Fairings and Seals Installation (Sheet 1 of 2)
Page 810
Revision 22 711010
MAINTENANCE MANUAL
4 FAIRING FOR 12 ASSY (NOTE)

3 FAIRING FOR 11 ASSY (NOTE)
MS20470AD2 RIVET (2)
9 PLATE
7 SUPPORT
0.19 IN.
(4.826 MM)
15 SEAL
0.44 IN. 0.19 IN.

(11.176 MM) (4.826 MM)
2.03 IN.
(5.1562 CM)
SECTION D D 369H9015141 FAIRING
ROTATED 180
MS3548919 GROMMET
SPLIT GROMMET APPROX.
AS SHOWN PRIOR TO INSTL.
369D23011
369H3003 FAIRING
11 FAIRING ASSY 0.250 IN. (6.35 MM) DIA.

THRU 11 FAIRING ASSY
TO MATCH EXISTING
NUTPLATE LOCATIONS
VIEW E E
ROTATED 90 CCW TYP. FOR
INSTL. OF 12 FAIRING ASSY
NOTE:
DRILL 0.063 IN. (1.6002 MM) DIA. HOLES IN
3 AND 4 FAIRINGS TO MATCH HOLES IN
9 PLATE (2 PLCS)
G7110142A
Figure 805. Auxiliary Fairings and Seals Installation (Sheet 2 of 2)
Page 811
711010 Revision 22
MAINTENANCE MANUAL
3.51 IN.
(8.9154 CM)
0.098 IN. (2.4892 MM) DIA. 3.20 IN.
(3 PILOT HOLES) (8.128 CM)
1.70 IN. (4.318 CM)
0.12 IN. (3.048 MM)
0.31 IN. 0.40 IN. (10.16 MM)
(7.874 MM) 0.80 IN. (20.32 MM)
0.43 IN. (10.922 MM)
0.68 IN. (17.272 MM)
0.37 IN.
5 (9.398 MM)
(4 PLCS)
BEND UP X 0.09 IN. (2.286 MM) R

(2 PLCS)
7 SUPPORT (FLAT PATTERN)
BEND UP X 0.09 IN. (2.286 MM) R

2.02 IN.
(5.1308 CM)
1.70 IN. (4.318 CM)
0.31 IN.
0.098 IN. (2.4892 MM) DIA. (7.874 MM)
(2 PILOT HOLES) 6 30 (4 PLCS)
0.12 IN. (3.048 MM)
0.35 IN. (8.89 MM)
0.77 IN. (19.558 MM)
0.23 IN. (5.842 MM)

0.31 IN. (7.874 MM)
0.80 IN. (20.32 MM)
0.40 IN. (10.16 MM)
0.37 IN. (9.398 MM) 3.50 IN.
(8.89 CM)
0.18 IN. (4.572 MM)
BEND DN X 0.09 IN. (2.286 MM) R
BEND UP X 0.09 IN. (2.286 MM) R

5 SUPPORT (FLAT PATTERN)
2.03 IN.
(5.1562 CM)
0.19 IN. 0.31 IN.
(4.826 MM) (7.874 MM)
0.44 IN.
0.75 IN. (19.05 MM) (11.176 MM)
0.0635 IN (0.16129 MM)
(#52 DRILL)
9 PLATE
G7110151A
Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 1 of 2)
Page 812
Revision 22 711010
MAINTENANCE MANUAL
30
0.95 IN. 1.70 IN.

(24.13 MM) (4.318 CM)
0.17 IN.
(4.318 MM)
1.56 IN.
(3.9624 CM)
0.93 IN.
(23.622 MM)
0.12 IN. (3.048 MM) R
0.81 IN. (2 PLCS)
2.00 IN.
(20.574 MM)
(5.08 CM) 0.06 IN. (1.524 MM) R
(2 PLCS)
5.63 IN.
(14.3002 CM)
0.18 IN. 2.13 IN.
(4.572 MM) 1.44 IN.
(5.4102 CM)
0.40 IN. (3.6576 CM)
(10.16 MM) 0.31 IN.
1.06 IN. (2.6924 CM) (7.781 MM)
1.50 IN. BEND DN 30 OPEN X

(3.81 CM) 0.12 IN. (3.048 MM) R
0.92 IN. (23.368 MM)

(2 PLCS)
0.12 IN. (3.048 MM) R
(2 PLCS)
30
BEND DN X
0.12 IN. (3.048 MM) R
(2 PLCS)
4 FAIRING (FLAT PATTERN) SHOWN

3 OPP.
G7110152A
Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 2 of 2)
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711010 Revision 22
MAINTENANCE MANUAL
NAMEPLATE
RETAINING SCREWS
SWITCH BODY
DIAPHRAGM RETURN
SPRING
DIAPHRAGM MAGNET
ASSEMBLY
SWITCH BODY
G711016
Figure 807. Pressure Switch
Page 814
Revision 22 711010
MAINTENANCE MANUAL

1. Engine Air Particle Separator Initial (10). On helicopters with cabin heat, remove
Installation cabin heat control valve to facilitate
installing part number
369H90148507, 519, or 527 particle
Consumable Materials separators.
Item Nomenclature Prevent engine FOD. Secure a
CAUTION cover over the engine intake be-
CM318 Primer
fore working in or around plenum chamber.
(11). Remove engine air inlet forward fairing
and aft fairing access cover.
(1). 369H90148519, 521, 527 and 529
particle separator installations are (12). Remove plenum chamber access door.
covered by procedures in this section.
(13). Disconnect forward end of tail rotor
NOTE: Tag components as they are removed, control rod at Sta. 95.00 bellcrank (Ref.
including attaching hardware. Protect loose Sec. 672010). Remove forward boot.
parts from damage, dirt or loss.
(14). Remove engine air cooling inlet screen.
(2). Ensure that battery switch and all
other helicopter switches are OFF. (15). Modify engine air cooling inlet screen
(Ref. Figure 903, view B).
(3). Open crew compartment left floor (16). Remove engine intake air inlet screen
access door and disconnect battery (Ref. Sec. 711000).
connector J108.
(17). Prepare airframe electrical ground
(4). Remove fairings from instrument panel points per FAA publication, EA
(Ref. Chap. 95). AC43.131A and 2A.
(5). Remove rotor brake cover, where (18). Using chemical film (CM206) treat
installed. reworked areas as required and apply
primer (CM318) except on electrical
(6). Remove map case and interior trim ground or bonding points.
panel (Ref. Sec. 253000).
A. Filter Bypass Door and Aft Cable
(7). Remove map case cover upper left
support bracket. (Ref. Figure 901)
(8). Remove transmission oil cooler inlet Consumable Materials

duct (Ref. Sec. 632100). (Ref. Section 910000)
Item Nomenclature
NOTE: Installation of bleed air extraction el-
bow, tee and hose with the engine in the he- CM410 Adhesive, epoxy (parts A & B)
licopter can be done; however, clearance is
minimal. (1). Modify the plenum chamber access door
(9). On helicopters without cabin heat, as follows:
remove engine to ease bleed air extrac- (2). Install clip and insert assembly on door
tion hardware installation prior to with screws, washers and nuts.
installing part numbers
369H90148509, 521, or 529 particle (3). Install latch assemblies on door with
separators. screws, washers and nuts.
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711010 Revision 22
MAINTENANCE MANUAL
FAIRING
HINGE (2 PLCS)
0.63 IN. (16.002 MM)

SCREW
1.250 IN. (3.175 CM)
SCREW
WASHER
NUT SCREW
PLENUM CHAMBER ACCESS DOOR LINK (2 REQD) WASHER
NUT
BOLT
NUT
WASHER
(NOTE 10) 1.250 IN. (3.175 CM)
BOLT
DOOR NUT 0.63 IN. (16.002 MM)
WASHER
PLATE (NOTE 10) CLIP
DOOR
(NOTE 1)
REMOVE REMOVE PLATE (2 REQD)

1.00 IN. (2.54 CM)
0.53 IN. (13.462 MM) SCREW

WASHER
NUTPLATE (4 PLCS) CLIP NUT
HINGE RIVET (8 PLCS)
(NOTE 4) (NOTE 3) (NOTE 13)
DOOR
SHIM
(NOTE 9)
COVER
(NOTE 6)
RIVET (4 PLCS)
(NOTE 5)
0.62 IN. (15.748 MM) (TYP)
1.250 IN. (3.175 CM) (TYP)
0.50 0.03 IN.

(12.70 0.762 MM)
FIBERGLASS
CLOTH (1 PLY)
0.50 0.03 IN. (12.70 0.762 MM) (NOTE 8)
FAIRING
0.56 0.03 IN. (14.224 0.762 MM)
GASKET 0.19 0.03 IN. (4.826 0.762 MM)
STA. (NOTE 7) STA. (NOTE 3)
141.00 DOOR INSTALLATION 131.00
G7110061A
Figure 901. Air Bypass Door Installation (Sheet 1 of 2)
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Revision 22 711010
MAINTENANCE MANUAL
LATCH
CLIP
SHIM
1.450 IN. (3.683 CM)

0.56 IN. (14.224 MM) (NOTE 1)
PLATE
LATCH 1.450 IN. (3.683 CM)
0.56 IN.
CLIP (14.224 MM) (NOTE 1)
1.62 IN. (4.1148 CM)
SHIM 0.68 IN. (17.373 MM) (NOTE 12)
PLATE
DOOR
1.62 IN. (4.1148 CM)
0.68 IN. (17.373 MM) (NOTE 12)
(REF)
STA.
136.00
GASKET
4.12 IN. 8.42 IN.
(10.4648 CM) (21.3868 CM)
0.91 IN. (23.114 MM) 2.00 IN. (5.08 CM)
CLIP DOOR
INSERT ASSY
NOTES:
1. DOOR PN 369A2099, 369H2087 AND 369D22087. 8. APPLY ONE PLY OF FIBERGLASS TO COVERTRIMMED DOOR
2. INSTALL COVER. TRIM DOOR TO MATCH CONTOUR OF COVER SO AFT EDGE PER DIMENSION SHOWN.
EDGE OF COVER OVERLAPS DOOR BY 0.19 IN. (4.826 MM) NOMINAL. 9. PEEL SHIM, AS REQUIRED, TO ALIGN DOOR AND FAIRING
REWORK NOT REQUIRED ON 369D290134 DOOR. EXTERNAL SURFACES FLUSH WHEN DOOR IS LATCHED.
3. INSTALL MS20426A035 RIVETS FLUSH ON HINGE NEAR SIDE. 10. TIGHTEN NUT TO GET 0.0050.015 IN. (0.1270.381 MM) GAP
4. CENTER NUTPLATES ON EXISTING 0.1960.210 IN. (4.97845.334 MM) DIA. BETWEEN BOLT HEAD AND WASHER.
HOLES IN HINGE. POSITION NUTPLATES AS SHOWN ON FAR SIDE IF HINGE. 11. DIMENSION TO MATCH LATCH AND BE CENTERED WITHIN
5. DRILL FAIRING TO MATCH HOLE PATTERN IN COVER. INSTALL FOUR 0.060 IN. (1.524 MM) WITH CLIP.
MS20470AD3 RIVETS. 12. DIMENSION TO MATCH CLIP AND BE CENTERED WITHIN 0.060 IN.
6. BOND COVER TO AFT FAIRING (REF. CSPDEF6). (1.824 MM) WITH LATCH.
7. MAKE GASKET FROM DE41 CLOSED CELL NEOPRENE RUBBER. BOND TO 13. CHAMFER UPPER EDGE TO EASE DOOR LATCH ENGAGEMENT.
DOOR WITH ADHESIVE (CM418).
G7110062A
Figure 901. Air Bypass Door Installation (Sheet 2 of 2)
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MAINTENANCE MANUAL
FAIRING BRACKET
ORIGINAL BRACKET BOSS
LOCATION
NEW BRACKET NOTE 2
LOCATION
SCREW (2 PLCS)
(NOTE 1)
1.65 IN. (4.191 CM)
CABLE TRAVEL
DOOR LATCHED
FAIRING 11 30" 0.29 IN. (7.366 MM)
DOOR OPEN B.L. 5.83 RH
CABLE STOP 0.39 IN. (9.906 MM)

1.375 IN.
(3.4925 CM)
SLEEVE VIEW LOOKING DOWN
EXISTING SCREWS,
FAIRING MODIFICATION,
BRACKET WASHERS, NUTS
UPPER RIGHT PULLEY
BRACKET
SCREW (2 PLCS)
GUARD PLATE FAIRING
SHIM SPACER
WASHER (NOTE 4)
NUT
WASHER PULLEY
(NOTE 3)
JAMNUT BUSHING
CABLE STOP
INSTALLATION
LOWER PULLEY
BRACKET
SCREW (2 PLCS)
G7110071A
Figure 902. Aft Cable Installation (Sheet 1 of 2)
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Revision 22 711010
MAINTENANCE MANUAL
DOOR CRANK
NUT
WASHER EXISTING SCREWS,
WASHERS, NUTS
CABLE TERMINAL
AFT FAIRING BRACKET
COTTER PIN
BOLT
CABLE
CONNECTION
FITTING BUSHING
WASHER (2 PLCS)
NOTES:
1. DRILL TWO 0.2170.229 IN. (5.51185.8166 MM) DIAMETER HOLES. NUT
COUNTERSINK 100 TO 0.43 IN. (10.922 MM) MINOR DIAMETER. UPPER PULLEY
2. FILL HOLES WITH ADHESIVE (CM410) OR EQUIVALENT. INSTALLATION PULLEY
(TYP 2 PLCS) (NOTE 3)
3. PULLEYS TO BE IN ALIGNMENT WITHIN 0.13 IN. (3.302 MM).
4. SHIM TO ALIGN CABLE WITH CABLE STOP WITHIN 0.060 IN. (1.524 MM).
G7110072A
Figure 902. Aft Cable Installation (Sheet 2 of 2)

(4). Attach links to latch and insert assem- stop into sleeve. Install washer and
bly with bolts, washers and nuts. cablestop jamnut.
Tighten nuts to get a 0.0050.015 inch
(0.1270.381 mm) clearance between (10). Install sleeve assembly in bracket.
boltheads and washers. Secure with washer and nut.
(11). Install door latch shims, clips, plates,
(5). Install door hinge nutplates with screws, washers and nuts (Ref.
rivets. Figure 901, view DD).
(6). Relocate upper right pulley bracket (12). Install bushing in lower pulley. Attach
mount holes (Ref. Figure 902, view B). pulley assembly to bracket with shim
Drill 0.2170.229 inch (5.51185.8166 between pulley and bracket. Install
mm) diameter holes. Countersink 100 guard plate, spacer, screws and washers
to 0.430 inch (10.922 mm) diameter. Fill over pulley. Attach the assembled
original holes with EA9314 epoxy pulley bracket to fairing with screws,
adhesive (CM410) mixed per manufac- washers and existing nuts (Ref.
turers instructions. Figure 902 detail C).
(7). Install upper pulley brackets using (13). Install air bypass door on aft fairing
existing fasteners. Insert bushings in with screws, washers and nuts.
two upper pulleys. Route cable assem-
bly over pulleys. (14). Screw fitting (Ref. Figure 902, detail E)
onto cable terminal. Install fitting in
(8). Install pulleys and cable assembly in insert assembly crank arm with washer
brackets; install pulley bracket bolts, and nut. Tighten nut to get a
washers and nuts. 0.0050.015 inch (0.1270.381 mm) gap
between crank and fitting head. Install
(9). Install cablestop bracket and shim cotter pin. Bend cotter pin only enough
using existing fasteners. Thread cable to keep it in place. Door rigging adjust-
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711010 Revision 22
MAINTENANCE MANUAL
ments will be required later to complete (3). Cover saw cut with a single ply of glass
the installation. cloth (Ref. Figure 901, detail CC) and
per Structural Repair Manual, CSP
(15). Add or peel latch clip shims to align DEF6.
door and fairing external surfaces flush
with door closed and latched (Ref. C. Handle and Forward Cable Installation
Figure 901).
(Ref. Figure 903)
(16). Check pulley alignment. Pulleys shall
line up within 0.130 inch (3.302 mm) of Consumable Materials
each other. (Ref. Section 910000)
Item Nomenclature
(17). Locate seal supports on fairing. Drill CM318 Primer
fairing to match holes in supports.
Install rivets (Ref. Figure 904, detail A).
Special Tools
(18). Install seals on supports. Align LH (Ref. Section 910000)
seals (Ref. Figure 904, detail A, sections Item Nomenclature
AA and CC). ST2007 Rivnut installation speed header
ST2008 Rivnut keyway cutter
(19). Remove coax, antiice and wire harness
cable support hardware, including clip
(Ref. Figure 904, views HH and JJ). (1). Remove 369H6524835 bracket (Ref.
Figure 903).
(20). Locate and rivet tyrap base in posi-
tion. Tie coax, antiice and wire (2). Remove oil pressure sender tube
harness in one bundle. Secure bundle to assembly from frame hole at canted
base with tyraps. Sta. 78.50.
(3). Enlarge oil pressure sender tube
B. Cover Installation
bulkhead hole to 0.042 inch (1.0668
mm) diameter. Install grommet.
(4). Modify map case or rotor brake cover
Item Nomenclature
(Ref. Figure 903, Sheet 3). Use flycut-
ter as required.
CM418 Cement, epoxy
(5). Attach control handle identification
decal to map case.
NOTE: 369D series helicopters equipped with
engine inlet fairings other than part num- (6). Drill and deburr rivet holes in angle,
bers 369A3053505, 507 and 509 require brackets and mount. Install brackets
modification of the air bypass door to clear and mount.
particle separator and the installation of a (7). Insert cable end into handle. Fit two
cover on the fairing (Ref. Figure 901, detail retainer halves over swaged ball. Pull
B). assembly back into handle to secure.
Install button plug.
(1). Use cover as a template and drill a
0.098 inch (2.4892 mm) diameter hole (8). Route cable assembly through bracket
in four places. Bond cover to fairing and secure with nut and washers. Stack
using bonding adhesive (CM418). washers as required to adjust handle
Install rivets. protrusion into cabin.
(2). Trace aft edge of cover onto bypass door. (9). Trim fairing to get a 0.120 inch (3.048
Remove door and cut away material mm) diameter gap between main rotor
0.190 inch (4.826 mm) forward of trace mast and fairing (Ref. Figure 903, view
line. F).
Page 906
Revision 22 711010
MAINTENANCE MANUAL
(10). Locate rivnut installation point (Ref. D. Bleed Air System Installation (Helicopters
Figure 903, view A). Drill one Without Cabin Heat)
0.2500.256 inch (6.356.5024 mm)
diameter hole through pan. Use a Consumable Materials
C3576 key cutting tool (ST2008) to (Ref. Section 910000)
make a 0.0620.065 inch (1.57481.651 Item Nomenclature
mm) wide by 0.0560.058 inch
(1.42241.4732 mm) deep rivnut CM112 Antiseize compound high temperature
keyway. Apply primer (CM318) to hole.
Install rivnut with a C6000 speed Compressor bleed air is hot
header (ST2007) while primer is wet. CAUTION enough to char tube identifica-
tion tapes that may cause FOD. Remove
(11). Inspect rivnut installation. Rivnut identification tapes from compressor bleed
length measured from upper surface of air tubes prior to installation.
head to blind end shall be between NOTE:
0.3650.415 inch (9.27110.541 mm).
Rivnut shall be tight. D Helicopters without Cabin Heating re-
quire the installation of compressor bleed
air hardware on the engine for the par-
(12). Secure cable to rivnut with a clamp, ticle separator scavenge air system.
washer and screw. D Installation of bleed air extraction elbow,
tee and hose with the engine installed in
the helicopter can be done; however,
(13). Install grommet in fairing (Ref.
clearance is minimal.
Figure 903, view D). Route cable
through grommet. D Apply high temperature antiseize com-
pound (CM112) to male threads of all fit-
tings prior to installation.
(14). Locate and drill 0.390 inch (9.906 mm)
diameter hole through left fairing for (1). Remove engine (Ref. Sec. 7100).
pressure switch tube union (Ref.
(2). Continue with Scavenge Air System
Figure 904, Sheet 1). Do not install
Installation.
union at this time.
E. Bleed Air System Installation (Helicopters
With Cabin Heat)
(15). Locate pressure switch support angle
position (Ref. Figure 904, Sheet 1). Drill
and deburr rivet holes. Install angle Consumable Materials
with rivets. Do not install pressure (Ref. Section 910000)
switch at this time. Item Nomenclature
NOTE: Ground connection (E45) requires mini-
mum resistance to current flow for reliable Compressor bleed air is hot
solenoid air valve operation. CAUTION enough to char tube identifica-
tion tapes that may cause FOD. Remove
identification tapes from compressor bleed
(16). Prepare electrical ground (E45) stud air tubes prior to installation.
installation per FAA publication,
EAAC43.131A and 2A. NOTE: Apply high temperature antiseize
compound (CM112) to male threads of all fit-
tings prior to installation.
(17). Install ground stud screw through
existing tool hole in stringer with (1). Remove cabin heat control valve.
washers, jamnut and nut. Install decal Remove existing control valve elbow
(Ref. Figure 907, detail B). and Oring.
Page 907
711010 Revision 22
MAINTENANCE MANUAL
0.250 IN. (6.35 MM) DIA. HOLE

TO MATE WITH EXISTING
NUTPLATES (6 PLCS)
PARTICLE SEPARATOR
MAP CASE RIGHT FAIRING
LEFT FAIRING
5.555.68 IN.
(14.09714.4272 CM)
FORWARD CABLE
5.555.68 IN. RIVNUT, CLAMP,

(14.09714.4272 CM) SCREW, WASHER
ENGINE INLET
FAIRING
TOP VIEW LOOKING DOWN
ENGINE AIR COOLING

INLET SCREEN
GRIND OFF SHADED AREA IN

SEPARATOR INTERFERES WITH FITTING
0.25 IN.
(6.35 MM)
45 ANGLE
1.00 IN.
(2.54 CM)
ENGINE AIR COOLING INLET

MAST SUPPORT FITTING SCREEN MODIFICATION
G7110081A
Figure 903. Handle and Forward Cable Installation (Sheet 1 of 3)
Page 908
Revision 22 711010
MAINTENANCE MANUAL
6.566.80 IN. (16.662417.272 CM)

CABLE
0.881.12 IN. PULLEY

(22.35228.448 MM)
CABLE CONNECTOR
RETAINER
RETAINER SPRING
GROMMET
SCREW
CABLE
CLIP
LEFT FAIRING
CLAMP
WASHER
MAST SUPPORT
NUT
CABLE HOUSING
FAIRING 0.12 IN. (3.048 MM) DIA.

CLEARANCE
G7110082A
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711010 Revision 22
MAINTENANCE MANUAL
0.70 IN. (17.78 MM) DIA. HOLE

IN TRIM PANEL TO MATCH TORQUE GAGE
CABLE FITTING TUBE (REF)
OIL PRESSURE TUBE
ENLARGE HOLE TO 0.42 IN.

(10.668 MM) DIA.,
INSTALL GROMMET
OPTIONAL ROTOR HEATER CONTROL

BRAKE HANDLE (REF) CABLE
DECAL
0.22 IN. (5.588 MM) DIA.

HOLE IN TRIM PANEL TO
MATCH SHOCK MOUNT EXISTING RIVET
LOCATION
0.096 IN. (2.4384 MM)
DIA. HOLE (8 PLCS)
CANTED STA. 78.50
0.22 IN. (5.588 MM)
RIVET EDGE TORQUE GAGE TUBE
OPTIONAL ROTOR
DISTANCE (TYP) (REF)
BRAKE COVER (REF) MAP CASE OR OPTIONAL
ROTOR BRAKE COVER
GROMMET
WASHERS, AS REQUIRED, TO
ADJUST HANDLE PROTRUSION
MAP CASE OR OPTIONAL OIL PRESSURE

ROTOR BRAKE COVER SENDER TUBE (REF)
FORWARD CABLE
CABIN HEAT CONTROL

CABLE END FITTING CABLE (REF)
RETAINER HALVES NUT
0.44 IN.
BRACKET (11.176 MM)
SHOCK MOUNT 0.73 IN. (18.542 MM)

0.096 IN. (2.4384 MM) ANGLE
DIA. HOLE (2 PLCS)
RIVET (2 PLCS)
BYPASS DOOR
HANDLE
0.28 IN. (7.112 MM) RIVET EDGE
BUTTON DISTANCE (TYP), PICK UP EXISTING
RIVET LOCATIONS 0.95 IN.
(24.13 MM)
HANDLE SUPPORT BRACKET INST
G7110083A
Page 910
Revision 22 711010
MAINTENANCE MANUAL
(2). Install special threeport elbow and (2). Attach one end of compressor bleed air
Orings with existing fasteners. Torque tube to special threeport elbow. Torque
threeport elbow flange selflocking tube nut to 110 130 inchpounds
nuts up to 18 inchpounds (2.03 Nm). (12.43 14.69 Nm).
Install cabin heat control valve. Torque
nuts to 20 25 inchpounds (2.26 (3). Bolt solenoid valve to bracket. Attach
2.82 Nm). free end of bleed air tube assembly to
solenoid valve. Torque tube nut to 110
(3). Install universal elbow, Oring and 130 inchpounds (12.43 14.69 Nm).
jamnut on engine compressor scroll.
Do not scratch or gouge firewall
Torque jamnut to 145 155 inch CAUTION surface when trimming heat
pounds (16.38 17.51 Nm) (Ref.
Figure 905). shield.
(4). Mark solenoid valve bracket position on
(4). Install tee, jamnut and Oring on firewall heat shield pad. Remove
compressor diffuser duct. Torque tee bracket, valve and tube. Cut an 0.125
jamnut to 285 315 inchpounds inch (3.175 mm) oversize opening
(32.20 35.59 Nm). through heat shield pad for the valve
mounting bracket.
(5). Install hose assembly between elbow
and tee. Torque hose nuts to 150 250 (5). Drill and deburr valve bracket rivet
inchpounds (16.95 28.25 Nm). holes.
(6). Install cover, spacer and gaskets on (6). Install bracket on firewall with six
special threeport elbow with bolts, rivets.
washers and nuts.
(7). Mount solenoid valve on bracket.
(7). Loosely install special threeport elbow Torque valve mounting bolts to 20 25
on canted firewall with bolts, washers inchpounds (2.26 2.82 Nm).
and nuts.
(8). Install scavenge air tube between the
(8). Install nut and Oring on 0.750 inch valve and elbow. Torque tube nuts 110
(19.05 mm) universal elbow and install 130 inchpounds (12.43 14.69 Nm).
in threeport elbow. Torque threeport
(9). Install elbow on scavenge air line
elbow flange selflocking nuts up to 18
support bracket (Ref. Figure 904, view
inchpounds (2.03 Nm). Torque
GG) with one washer on each side.
universal elbow jamnut 285 315
Install and torque jamnut to 120 150
(9). Install engine (Ref. Sec. 7100). (10). Trim away up to 0.050 inch (1.270 mm)
of bracket outboard edge to clear
(10). Install tube assembly between firewall
intersecting angle and rivet heads.
mounted universal elbow and teefit-
Install support assembly on shelf with
ting. Torque tube nuts to 460 500
washers and screws.
(11). Locate scavenge air line elbow doubler
F. Scavenge Air System Installation on plenum chamber bulkhead. Fasten
doubler to structure with rivets.
(Ref. Figure 905)
(12). Install elbow, washer and nut on
(1). The scavenge air system consists of a doubler. Torque elbow jamnut to 120
solenoid air valve, tubes, air pressure 150 inchpounds (13.56 16.95 Nm).
switch, SCAV AIR circuit breaker
switch, AIR FILTER CLOGGED (13). Install upper scavenge air tube between
caution light, wiring, and attaching elbows. Torque tube nuts 110 130
hardware. inchpounds (12.43 14.69 Nm).
Page 911
711010 Revision 22
MAINTENANCE MANUAL
SEALING COMPOUND SEAL

(NOTE 6) (NOTE 7) SEAL
SUPPORT
TRIM RIVET (2 REQD)

SCREW, (NOTE 8) 0.84 IN.
DETAIL (21.336 MM)
WASHER SCREW, WASHER
(NOTE 1) SPACER
PARTICLE
SEPARATOR MIST ELIMINATOR
TAIL ROTOR SHAFT

TUNNEL (REF)
CL
5.21 IN.
1.11 IN. (13.2334 CM)
(2.8194 CM) 2.943.06 IN.
(7.46767.7724 CM)
1.361.48 IN.
(3.45443.7592 CM)
SCREEN
BYPASS TAIL ROTOR PITCH
FAIRING ASSY DOOR CONTROL ROD (REF)
CABLE GROMMET
0.39 IN. (9.906 MM) SCREW, STA. SEE STA.

DIA. HOLE THRU WASHER 127.00 DETAIL 131.00
FAIRING (NOTE 2)
TOP VIEW
G7110091A
Figure 904. Modifications and Installation (Sheet 1 of 4)
Page 912
Revision 22 711010
MAINTENANCE MANUAL
PARTICLE SEPARATOR PARTICLE SEPARATOR

MOUNTING FRAME MOUNTING FRAME
SEAL PARTICLE SEPARATOR

(NOTE 3) (REF)
FORWARD FLANGE,
SUPPORT PARTICLE SEPARATOR
SUPPORT
SCREW,
0.43 IN. WASHER
(10.922 MM)
0.31 IN. (7.874 MM)
DRILL FAIRING
TO MATCH
DRILL FAIRING
SUPPORT SEAL TO MATCH
SUPPORT
NUTPLATE FAIRING PARTICLE

SEPARATOR
SEAL
(NOTE 3)
SECTION SECTION SECTION
SEALING COMPOUND
(NOTE 6)
FAIRING
MAST SUPPORT
FITTING
INLET FAIRING
0.250 IN. (6.35 MM)

GROMMET DIA. HOLE
(NOTE 5) (NOTE 4)
VIEW
G7110092A
Figure 904. Modifications and Installation (Sheet 2 of 4)
Page 913
711010 Revision 22
MAINTENANCE MANUAL
TAPE
(NOTE 9)
TUBE ASSY, 0.38 IN.

TORQUE TO (9.652 MM)
2535 IN. LB
(2.823.95 NM)
UNION, WASHERS,
JAMNUT, TORQUE
TO 6580 IN. LB
(7.349.04 NM)
VIEW MIST ELIMINATOR

MAST SUPPORT
FITTING (REF) MOUNTING CLIPS
SUPPORT
SCREW,
TUBE ASSY TRIM WASHER
(NOTE 12) (NOTE 10)
WASHER,
SWITCH ASSY WASHER, SUPPORT
NUT
ELBOW
ENGINE INLET SCAVENGE AIR
ASSY (REF) TUBE ASSY
SIDE VIEW
TRIM
(NOTE 11) TUBE, TORQUE TO
VIEW 110130 IN. LB
(12.4314.69 NM) FWD
JAMNUT, TORQUE TO
120150 IN. LB INLET FAIRING
(13.5616.95 NM) (REF)
MAST SUPPORT
(REF)
STA.
127.00
CLIP SCREW,
(REMOVE) CLAMPS
(REMOVE)

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MD Helicopters, Inc.

MDHI 369D/E/FF - 500/600N HELICOPTERS

This manual has been reprinted and now contains

PRINT DATE: 10 May 2010

Basic Handbook of Maintenance Instructions

Copyright E 19992010 by MD Helicopters, Inc. Issued: 31 October 1990

RECORD OF TEMPORARY REVISIONS

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LIST OF EFFECTIVE PAGES

Chapter 04 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36

303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 203000

801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 623000

410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 632510

643000 525 and 526 . . . . . . . . . . . . . . . . . . . . . Revision 36

504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22

Chapter 75 208 thru 211 . . . . . . . . . . . . . . . . . . . . . Revision 37

06 DIMENSIONS AND AREAS

07 LIFTING AND JACKING

08 LEVELING / WEIGHT AND BALANCE

10 PARKING AND MOORING

11 PLACARDS AND MARKINGS

18 VIBRATION AND NOISE ANALYSIS

Section Title 369D 369E 369FF 500N 600N

21 ENVIRONMENTAL CONTROL SYSTEM

Section Title 369D 369E 369FF 500N 600N

Section Title 369D 369E 369FF 500N 600N

75 ENGINE ANTIICE SYSTEM

76 ENGINE POWER CONTROLS

78 ENGINE EXHAUST SYSTEM

79 ENGINE OIL SUPPLY SYSTEM

TABLE OF CONTENTS (Cont.)

This Page Intentionally Left Blank

MAIN ROTOR INSTALLATION

FORWARD SECTION MAIN TRANSMISSION AND

ENGINE ACCESS DOOR ASSEMBLY

CARGO DOOR ASSEMBLY

LOWER SECTION INSTALLATION

Figure 1. Helicopter Major Components (Sheet 1 of 3)

VERTICAL STABILIZER ASSEMBLY

MAIN ROTOR INSTALLATION

SAS CONTROL ACTUATOR

CARGO DOOR ASSEMBLY

LOWER SECTION INSTALLATION

Figure 1. Helicopter Major Components (Sheet 2 of 3)

6BLADED MAIN ROTOR